Download LightGuard Installation Manual

“Pursuing Safety Through Technology”
US Patent # 6,384,742
THE LIGHTGUARD SYSTEMS®
INSTALLATION AND USER MANUAL &
FACTORY RECOMMENDED GUIDELINES
Copyright  1999 LightGuard Systems, Inc.
March 2013
LightGuard Systems, Inc.
2292 Airport Blvd.
Santa Rosa, CA 95403-1003
707-542-4547 Ph.
707-525-6333 Fax
www.crosswalks.com
Copyright  1999 by LightGuard Systems, Inc. (LGS). All rights reserved. Printed in the United States of America. Except
as permitted under the Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by
any means, or stored in a database or retrieval system, without the prior written permission of the publisher. This information
is provided for information purposes only. LGS disclaims all warranties whether express or implied and specifically
disclaims all implied warranties of merchantability and fitness for a particular purpose. Failure to comply with
recommendations or guidelines will result in a void of product warranty.
®
LightGuard Systems Installation & User Manual (all rights reserved)
TABLE OF CONTENTS
1
THE LIGHTGUARD SYSTEM® AND COMPONENTS ............................................... 2
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
POWER SYSTEM AND COMPONENTS ................................................................... 6
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
3
INSTALLATION STEPS ................................................................................................................ 43
SOLAR MODULE .......................................................................................................................... 43
SOLAR SYSTEM BATTERIES ..................................................................................................... 45
CHARGE CONTROLER ................................................................................................................ 46
TROUBLE SHOOTING / MAINTENANCE / AFTER INSTALLATION ..................... 47
8.1
8.2
8.3
8.4
9
LED “ENHANCED” SIGN GENERAL DESCRIPTION ................................................................. 42
LED “ENHANCED” PEDESTRIAN CROSSING SIGN DRAWING .............................................. 42
LIGHTGUARD SYSTEMS SOLAR POWER OPTION ............................................. 43
7.1
7.2
7.3
7.4
8
MANUAL PUSH BUTTON ACTIVATION DESCRIPTION ............................................................ 40
ILLUMINATED PUSH BUTTON ASSEMBLY ............................................................................... 40
SAMPLE PUSH BUTTON LAYOUT AND WIRING DIAGRAM .................................................... 40
PUSH BUTTON INSTALLATION DETAIL DRAWING ................................................................. 41
LED “ENHANCED” ILLUMINATED WARNING SIGNS .......................................... 42
6.1
6.2
7
AUTOMATIC BOLLARD DETECTION SYSTEM DESCRIPTION ............................................... 31
BOLLARD DRAWING ................................................................................................................... 31
BOLLARD INSTALLATION GUIDELINES ................................................................................... 32
BOLLARD SENSOR ADJUSTMENT ............................................................................................ 34
BOLLARD ALIGNMENT ............................................................................................................... 34
BOLLARD DETECTION ZONE OPERATION .............................................................................. 36
UNI-BOLLARD / ISAD INSTALLATION OPTION ........................................................................ 37
PUSH BUTTON ACTIVATION ................................................................................. 40
5.1
5.2
5.3
5.4
6
GENERAL DESCRIPTION ............................................................................................................ 21
MAJOR CONSIDERATIONS FOR LIGHTGUARD SYSTEM IRWL INSTALLATION ................. 21
CONCRETE INSTALLATION PROCEDURE ............................................................................... 24
IRWL SIGNAL AND BASE PLATE INSTALLATION GUIDELINES ............................................ 25
IRWL SAW CUT CROSS-SECTION DIAGRAMS ........................................................................ 26
TYPICAL IRWL SIGNAL BASE PLATE WIRING DRAWING ...................................................... 27
CONVERGENCE ZONES .............................................................................................................. 29
AUTOMATIC ACTIVATION SYSTEM - SMART CROSSWALK™ .......................... 31
4.1
4.2
4.3.
4.4
4.5.
4.6.
4.7
5
POWER SYSTEM DESCRIPTION .................................................................................................. 6
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TYPICAL LIGHTGUARD SYSTEM WIRING DIAGRAM .............................................................. 6
AC SYSTEM .................................................................................................................................... 7
SOLAR SYSTEM ............................................................................................................................. 9
ECP SYSTEM (ECP-1 & ECP-2) ................................................................................................... 11
ENCLOSURE POLE MOUNT DETAIL.......................................................................................... 13
BACK PANEL ELECTRICAL CONNECTIONS ............................................................................ 13
POWER CONTROL UNIT (PCU) DESCRIPTION ......................................................................... 15
IN-ROADWAY WARNING SIGNAL (IRWL) ............................................................ 21
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4
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THE LIGHTGUARD SYSTEM ........................................................................................................ 2
POWER SYSTEM ............................................................................................................................ 2
IN-ROADWAY WARNING LIGHT (IRWL) SIGNAL HEAD ............................................................ 2
SYSTEM ACTIVATION; AUTOMATIC/MANUAL/CONTINUOUS/PROGRAM .............................. 2
LED “ENHANCED” PEDESTRIAN CROSSING SYMBOL SIGN .................................................. 3
LGS COMPONENTS NEEDED FOR A TYPICAL SMART CROSSWALK™ ................................ 3
SUGGESTED INSTALLATION EQUIPMENT, MATERIALS AND TOOLS ................................... 5
TROUBLE SHOOTING GUIDE ..................................................................................................... 47
FIELD RELATED TOTAL PREVENTATIVE MAINTENANCE ..................................................... 48
FIELD RELATED TOTAL PREVENTATIVE MAINTENANCE ..................................................... 48
EQUIPMENT LIST ......................................................................................................................... 49
ADDENDUMS .......................................................................................................... 50
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LightGuard Systems Installation & User Manual (all rights reserved)
1
THE LIGHTGUARD SYSTEM® AND COMPONENTS
1.1
THE LIGHTGUARD SYSTEM®
The LightGuard System (the System) is designed for applications at mid-block or uncontrolled
intersection crosswalks and other roadway crossings. It is entirely compliant with the MUTCD
and in many cases, the MUTCD text was composed with the LightGuard Systems product
development and testing in mind.
The System utilizes a series of light emitting diodes (LED’s) in a durable housing embedded in
the roadway which flashes, in a unidirectional manner, a warning to approaching motorists that a
pedestrian is in or entering the crosswalk. The in-roadway LED warning signals are aimed down
the motorist-viewing path of the approaching driver to allow the flashing lights to be easily seen
by motorists along the full length of the un-obscured viewing approach path. The lights flash for
a set period of time before automatically turning off. The System can be activated by a
pedestrian pushing a button, or automatically when a pedestrian passes through an activation
zone breaking an optical beam. It can be a stand-alone solar-powered System, or a
conventional AC powered System with battery back up.
The LightGuard System comprises the following components and all components must work in
unison.
1.2
POWER SYSTEM
A roadside, or pole mounted, cabinet contains all of the LED drive electronics and field wiring
electrical interfaces. Both the AC & the ECP systems operate off a 12 VDC power supply from
an AC line. The AC system can be energized from either 110V single phase or 220V two-phase
power. The ECP can only be energized from 110V single phase. The Solar System operates off
of 12 VDC battery power and is recharged during daylight hours from a Solar PV panel.
Based on a typical installation, power usage is approximately 18 - 20 watts depending on the
type of activation mechanism. Total energy consumed (in KWH) is dependent upon the number
of light fixtures, the cross time duration, and the number of activations. Circuit breakers protect
internal circuitry and field wiring. The Power Control Unit (PCU) available in the AC & Solar
Systems is based on a high speed 8 bit embedded microcontroller utilizing a compiled machine
control language. LGS proprietary software program provides effective, reliable operation
allowing the user simple operation adjustments with a keypad and display (LCD).
1.3
IN-ROADWAY WARNING LIGHT (IRWL) SIGNAL HEAD
The LightGuard System™ In-Roadway Warning Light signal heads are manufactured of high
strength impact resistant materials. They are designed to be mounted onto a metal or composite
base plate assembly that is permanently attached to the roadway. This allows for easy
replacement of any IRWL that may become damaged, or inoperable, for any reason.
1.4
SYSTEM ACTIVATION; AUTOMATIC/MANUAL/CONTINUOUS/PROGRAM
1.4.1 AUTOMATIC - Bollards
For AUTOMATIC activation, the System uses state-of-the-art electronic and software driven
technology. The Smart Crosswalk™ automatic system is a dual break-beam system utilizing
modulated infrared sensors housed in decorative posts, or bollards, at each side of the
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LightGuard Systems Installation & User Manual (all rights reserved)
crosswalk. Direction of pedestrian travel is detected and allows activation of the System only
upon entry, not when exiting. Custom designed bollards currently house the drive electronics for
automatic activation. They can be positioned up to 50 ft. (15m) apart.
1.4.2 MANUAL - Push Button or optional Key Switch operation
A standard push button assembly (if installed) may be depressed if the pedestrian chooses to
MANUALLY activate the System. Unlike existing signage, when the pedestrian pushes the
button an “ON” response from the System is immediately visible via flashing LED lights above
the words “CROSS WITH CAUTION”. As an added benefit, the PCU automatically monitors
frequency and direction of use. Other activation options include pre-set on-off times or Key
Switch activation with a set “on” time operation. Keypad functions allow for up to three (3)
automatic on-off times for each day of the week.
1.4.3 CONTINUOUS – CONSTANT ON
The Illuminated crosswalk system can be set for continuous flashing 24/7. This is NOT
recommended for solar powered systems due to the continuous power drain affecting battery
recharge.
1.4.4 PROGRAMMABLE – Pre-set on/off timer
The Illuminated crosswalk system can be programmed to activate for a predetermined duration
with 3 different start stop times up to 7 days per week. Refer to section 2.8.4.11 for instructions.
1.5
LED “ENHANCED” PEDESTRIAN CROSSING SYMBOL SIGN
It is recommended that a new fluorescent-yellow-green color (FYG), diamond-shaped pedestrian
crossing sign (W11A-2) with LED warning light modules at the “enhanced” flash rate, is installed
with each System (FYG S2-1 or W66 type school symbol sign also available). The LED warning
light modules are designed to flash in conjunction with activation of the System. This active LED
pedestrian crossing sign enhances driver recognition of the System’s presence, especially in
adverse weather conditions, and contributes to educating the motorist as to the meaning of the
flashing array of in-roadway warning signals. The new W11A-2 sign, with the LightGuard
embedded LED warning light modules, replaces the standard W-54 sign typically placed at the
crosswalk site.
1.6
LGS COMPONENTS NEEDED FOR A TYPICAL SMART CROSSWALK™
(Typical Four Lane Roadway Crossing)
ITEM
QTY SYSTEM DESCRIPTION
1)
1
LightGuard Power Control Unit (PCU)
This PCU is based on a high speed 8 bit embedded microcontroller utilizing a
compiled machine control language. A keypad and LCD display is provided to
allow simple user adjustments to the System parameters. The PCU includes
LGS’s proprietary software program.
2)
1
Electronics Enclosure
The enclosure is sized to allow mounting of all components necessary to control
the System. The enclosure’s water-resistant design is based upon the United
States National Electronic Manufacturer’s Association (NEMA) specifications.
3)
18
LGS In-roadway Warning Signal Assemblies
The In-roadway Warning Signal assemblies are street-mounted to withstand
normal vehicle traffic. The patent protected assemblies, including base plates, are
a LGS proprietary design.
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4)
4
Automatic Activation System Bollards
Pedestrian detection bollards or posts for automatic activation of the Smart
Crosswalk™ System are located at each crosswalk entrance zone. Optical beam
interruption sensors are designed to activate the System automatically as the
primary activation mechanism of the System.
5)
2
LED Enhanced Pedestrian Symbol Warning Sign
The fluorescent-yellow-green (FYG) color, diamond shaped pedestrian warning
sign (W11A-2) is retrofitted with LED warning light modules. LED light modules are
designed to flash at the same flash rate & in conjunction with activation of the
LightGuard System™.
6)
Lot Mount Assemblies
LGS approved standard mount assemblies are sized and configured appropriately
to allow mounting of the enclosure, automatic activation sensors, active signs, and
other any other equipment required to operate the System. Fasten hardware not
included - tamper resistant hardware is recommended for sign attachment to
mount assembly.
7)
Lot Signal Head Spare Parts
Gel-plugs and O-ring.
8)
Lot Cable/wiring
LGS approved multi-strand 8 conductor wiring (BELDEN 27601A), 18 AWG, can
be provided to connect the activation assemblies to the System PCU. Stranded
wire, 14 AWG, type RHW-2/USE-2/XLP (colors - BLK YEL & RED), maximum
OD 0.17” (4.3 mm) can be provided to connect the In- Roadway Warning Signal
assemblies to the System PCU.
OPTIONAL EQUIPMENT
9)
Solar Power Assembly and Enclosure
Solar Power Assembly with modules includes; battery charge amp/load controller,
sealed solar cell batteries, battery cable, wire, fusing, and T-blocks sized to
adequately operate System.
10)
ECP Assembly and Enclosure
ECP Assembly includes flashing unit controller and power supply
11)
AC Beacon Interface
Modified PCU & DIN Rail connections for 2 separate 115VAC relays operating in
either wig-wag or continuous mode
12)
DC Beacon Interface
Modified PCU & DIN rail connections for 2 separate 12VDC relays operating in
either wig-wag or continuous mode
13)
Audible crosswalk Interface
Modified PCU and DIN rail connections for various audible systems (voice, chirp,
tweet, etc.)
14)
Dual Zone Upgrade Kit
Modified PCU & DIN rail connections for 2 independent cross walk zones
(activates flashing at 2 separate crosswalks)
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1.7
SUGGESTED INSTALLATION EQUIPMENT, MATERIALS AND TOOLS
The general list below may include all equipment, materials, or tools required for installation.
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Typical electrical tools used in street lighting and signal work
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
•
•
•
•
•
•
•
•
•
•
Inch pound torque wrench
End wrenches & sockets
Crescent wrenches
Allen wrenches
Hammers - 3 lb. (1.5kg) & claw
Hack saw, File, & Knife
Wire strippers
Slip Joint Channel Lock Pliers
Chisel
1/8” hex socket
•
•
•
Taps & Dies
2 Putty knives x 4” (100mm) wide
Cordless drill with assorted bits 0.250” (6.3mm)
to 1” & hole saws 1” & 1½” (25mm & 38mm)
•
•
•
•
•
•
Rotor hammer – 1” bit & 1½” bit
Skill saw & blades
Small hand held grinder
Latex gloves – disposable
AC DC meter
Container and mixing tool for 2-part adhesive
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
•
•
•
100 ft (30m) measuring tape
• Duct Seal
Black & red electrical tape
• Fish tape
Grinding Core Drill: Best Practice Custom “Flat Bottom” Core Drill: Best Practice
Custom “Flat Bottom” Core Drill to eliminate the need for removing excess material from
cored depression cut. Contact LightGuard Systems for more information about
availability.
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
•
•
•
Air-blower (compressor)
Broom & dust pan
1 Hose -garden type & fire hydrant adaptor
•
•
•
Wheelbarrow
Shovel – square point & round point
Rope
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
•
•
•
•
•
•
•
Loop (saw cut) sealant
• 6 sack mortar mix (base of poles & boxes)
Conduit sealer
• 90lb (40kg) sack of sand
BONDO 7084 Adhesive (industrial 2-part epoxy) refer to section 3.2.7
5-gallon (20L) pail of ¾” (19mm) rock for under traffic valve boxes
Generator, with extension cord, for auxiliary power
Cut-off, mixed fuel, & spare blades
Power driven asphalt (saw) cutter capable of cutting ½” (12mm) wide x 2” (50mm) deep
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
•
•
1¼” (32mm) minimum conduit as required by local agency
(sizes can be determined by site engineer)
Reel wire holder ½” (12mm) diameter x 36” (1m) long on stand (optional)
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
• ALL NECESSARY EQUIPMENT FOR IMPLEMENTING AN
APPROVED TRAFFIC CONTROL PLAN
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------
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LightGuard Systems Installation & User Manual (all rights reserved)
2
2.1
POWER SYSTEM AND COMPONENTS
POWER SYSTEM DESCRIPTION
An AC powered system uses either 115VAC single phase or 230VAC two phase as an energy source.
A DPST 5A circuit breaker protects the both the Line and Neutral for single phase OR both Lines for
two phase input. The AC power is transformed to 13.5 VDC via a 150W power supply. The 5A DPST
circuit breaker is marked by the factory for both Line & Neutral, with one pole of the 5A DPST circuit
breaker labeled “hot black” and the other labeled “neutral white”. For 2 phase operation, the label
marked “neutral white” must be removed or otherwise placard over & the power supply switch must be
reset to 230V prior to energizing the main 5A DPST circuit breaker on the back panel. The switch
setting is normally factory configured for 115V & MUST BE RESET at time of installation for 2 phase
230V source. Refer to section 2.3.3 for switch location.
A Solar powered system uses a minimum 75W Photovoltaic array providing DC power to the internal
batteries. All branch circuits have their own independent circuit protection in the Electronics Enclosure.
An ECP system uses 115VAC single phase as an energy source. A DPST 5A circuit breaker protects
the both the Line and Neutral. The AC power is transformed to 13.5 VDC via a 150W power supply.
2.2
TYPICAL LIGHTGUARD SYSTEM® WIRING DIAGRAM
NOTE: This is a reference diagram only, connections shown are not applicable to all installations.
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LightGuard Systems Installation & User Manual (all rights reserved)
2.3
AC SYSTEM
2.3.1
AC ENCLOSURE DESCRIPTION
The hasp latch locking enclosure is included with the LightGuard System®. The Aluminum enclosure
(UL 50 standards and NEMA 3R) & Fiberglass Enclosure (NEMA 6) contains the control panel
components and can be mounted to a pole or wall. Adjustable mounting brackets are provided with
enclosure (mounting hardware not included, specific hardware to be supplied by installer). The all
aluminum enclosure (no longer stock item – special request only) comes standard with a white powder
coat finish & contain knock-outs on the rear for ½” NPT connectors (refer to sections 2.3.2 & 2.4.2)
2.3.2
AC ENCLOSURE OUTLINE DRAWING
16.2”
21.2
8”
NEMA 3R Aluminum Enclosure
(Special Request Only)
2.3.3
NEMA 6x Fiberglass Enclosure
(Standard Model)
AC BACK PANEL LAYOUT
ENCLOSURE
Sunsaver
POWER SUPPLY
(Charge Controller)
PCU (Power Control Unit)
POWER SUPPLY
phase switch
setting location
BACKUP BATTERY
TERMINAL
BLOCKS
FILTER
CIRCUIT BREAKERS
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2.3.4
AC BACK PANEL SCHEMATIC
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2.4
SOLAR SYSTEM
2.4.1 SOLAR ENCLOSURE
Solar powered Systems are free-standing pedestal mount or pole mount enclosures. Aluminum
cabinets contain knock-outs on the rear for ½” NPT connectors (refer to sections 2.3.2 & 2.4.2).
14.5”
(368mm)
45”
(1143mm)
16.2”
(412mm)
2.4.2
SOLAR BACK PANEL LAYOUT
PCU (Power Control Unit)
BATTERY CHARGE
CONTROLLER
TERMINAL BLOCKS
CIRCUIT BREAKERS
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2.4.3
SOLAR BACK PANEL SCHEMATIC
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2.5
ECP SYSTEM (ECP-1 & ECP-2)
The ECP system differs from the AC & SOLAR systems in several ways. All user INPUT connections
are made directly to the Flashing Unit Controller Subassembly.
This system in NOT field
programmable, only cross time is user selectable. Refer to section 2.5.4 for additional information.
2.5.1 ECP ENCLOSURE
The enclosure is a NEMA4X Fiberglass structure designed for wall or pole mounting only. Uni-strut
brackets are provided with enclosure (mounting hardware not included, specific hardware to be
supplied by installer). Electrical connections can be made by drilling access holes either on the bottom
or the lower region on the rear of the enclosure. The enclosure has sufficient clearance to support up
to one 1½” NPT connector on the rear, and several 1½” NPT connectors on the bottom. The standard
enclosure color is white.
2.5.2
ECP BACK PANEL LAYOUT
12VDC
Power
supply
Main AC
Circuit
Breaker
Flash Unit
controller
AC power
connection
(Line/Neutral)
Field Wiring to
Bollards, Push
Buttons, &
AC Ground
connection
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2.5.3
ECP BACK PANEL SCHEMATIC
2.5.4
ECP FLASH UNIT PARAMETER ADJUSTMENTS
The ECP-1 has only one field adjustment, setting the cross time flash duration. This is set by rotating
the selector knob to the number of seconds required for the system to flash once activated. Cross time
can be set from 5 seconds to 100 seconds. The ECP will operate with Bollards &/or Push Buttons.
Status indicator lights on the Flashing Unit Controller Subassembly show an input activation & the
output flashing activation. There is also an LED to indicate that the system is energized. Lastly, there
is a test button which can be used for in-cabinet testing of the ECP System.
The ECP-2 can be factory configured for 2 independent outputs each triggered from the any of the
activation inputs. This system is customizable but with limitations. Contact LightGuard Systems for
specific custom configurations (ie: dual color IRWL and/or DC beacons with alternating flash patterns).
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2.6
ENCLOSURE POLE MOUNT DETAIL
All enclosures can be pole mounted using supplied Uni-strut brackets and appropriate hardware. The
ECP, AC, & SOLAR Systems use the identical brackets.
2.7
BACK PANEL ELECTRICAL CONNECTIONS
AC & SOLAR SYSTEMS
The AC & Solar back panels incorporate the system Power Control Unit (PCU), circuit breakers, and
backup battery charge controller. The PCU is field programmable & controls both signaling and timing
functions. The battery charge controller sequences battery charging and low voltage load disconnect.
ECP SYSTEM
The ECP back panel incorporates the ECP flash unit, circuit breakers, and DC power supply.
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2.7.1
TERMINAL BLOCK CONNECTION DEFINITIONS (DC ONLY +12VDC & 0VDC)
SYSTEM INPUTS (DC ONLY)
1A
Bollard Sensor 1st call signal side 1
} Bollards closest to enclosure
1B
Bollard Sensor 2nd call signal side 1
2A
Bollard Sensor 1st call signal side 2
} Bollards farthest from enclosure
2B
Bollard Sensor 2nd call signal side 2
PA
Normally open line from Push Button assembly closest to enclosure
PB
Normally open line from Push Button assembly farthest from enclosure
SWITCHED 12VDC OUTPUT (Enlighten1 pulse rate)
S+
In-roadway Warning Signal YEL &/or RED wire depending on IRWL color 2.7.2
S+
In-roadway Warning Signal YEL &/or RED wire depending on IRWL color 2.7.2
CONSTANT CURRENT SOURCE (12VDC Output For Use With Bollards Only)
B+
Bollard area LED courtesy lights & Sensor Power
B+
Bollard area LED courtesy lights & Sensor Power
DC GROUNDS (0 VDC)
GND
In-roadway Warning Signals DC Ground/Common
Push Button DC Ground/Common
Bollard Power DC Ground/Common
LED Push Button Placard DC Ground/Common
LED “Enhanced” Illuminated Pedestrian Symbol Crossing sign DC Ground/Common
2.7.2
TYPICAL ENCLOSURE “FIELD WIRING” TERMINAL BLOCK CONNECTIONS
ENCLOSURE TERMINAL BLOCK CONNECTIONS
FOR IN-ROADWAY WARNING SIGNALS:
1
A
1
B
2
A
2
B
P
A
P
B
S
+
S
+
B
+
B
+
R Y
E or E
D L
*
G G
N N
D D
B
L
A
C
K
G
N
D
G
N
D
Bollard Push Button SIGNAL Bollard
DC Ground
Sensor Inputs
Inputs Lighting Power (negative/common)
System Outputs
DRAWING NOT TO SCALE
NOTE: ALWAYS USE 14 AWG WIRING, TYPE RHW-2/USE-2/XLP MAX OD .17” (4.3mm) APPROVED BY LOCAL AGENCY FOR IN-ROADWAY
WARNING SIGNAL ARRAY HOME RUN CONNECTION. S+ POSITIVE CONDUCTOR COLOR IS DEPENDANT ON IRWL COLOR – RED IS
USED FOR RED IRWL, YEL IS USED FOR YEL IRWL. FOR ACTIVATION MECHANISM, ALWAYS USE 8 CONDUCTOR 18 AWG STRANDED
SIGNAL CABLE TO RUN FROM ENCLOSURE TO OPPOSITE SIDE OF STREET.
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2.8
POWER CONTROL UNIT (PCU) DESCRIPTION
The PCU is based on a high-speed 8 bit embedded microcontroller utilizing compiled machine control
language. A LightGuard proprietary software program provides effective, reliable operation allowing the
user to make simple adjustments to the System parameters with a keypad and liquid crystal display
(LCD).
2.8.1
TYPICAL POWER CONTROL UNIT (PCU) DRAWING
9 PIN D-SUB
CONNECTOR
LCD
LCD
ILLUMINATION
ADJUSTMENT
1
2
3
A
4
5
6
B
7
8
9
C
*
O
#
D
KEYPAD
“PUSH TO TEST”
BUTTON (ALT
LOCATIONS)
BOLLARD & BUTTON
INPUT INDICATORS LEDs (2 rows)
FUSES
PCU SYSTEM ACTIVATION INDICATOR
LED blinks when “Push to Test” button is pressed
2.8.2
POWER CONTROL UNIT (PCU) PARAMETER ADJUSTMENTS
The PCU is preprogrammed with easily adjustable parameters. To operate the System manually flip all
circuit breaker switches up to “ON” position. All functions are accessible from the keypad. A highcontrast liquid crystal display (LCD) provides easy read out of the settings. Pressing a key will display
data, or a parameter, on the LCD. Some keys will access a list of parameters. If no change is desired,
press the “#” key to escape or advance to the next parameter in that list. Pressing the “#” key can also
escape from a partially entered value. Each parameter has a required number of digits. The required
number must be entered or the number will default back to existing number.
The POWER CONTROL UNIT (PCU) KEYPAD FUNCTIONS TABLE describes programming the PCU
using the keypad and display. Generally when a menu is accessed using one of the numeric keys, the
user must complete all entries within that menu before the PCU will accept other menu parameter
inputs. In many cases, the # key will act as a “next” function advancing the menu without changing the
existing parameter in program memory. There is no “escape” key to undo keypad entries. If a keypad
error is made, the user must complete that function menu & then repeat that function menu with correct
keypad entries.
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Additional notes
INITIATING THE SYSTEM – When the PCU is energized for the first time, a message should
display on the LCD with instructions to contact LightGuard Systems Inc. for an ACTIVATION
CODE. This code is used for both system installation tracking & warranty tracking purposes.
CROSS TIME - Refer to local governing agency for System activation / crossing time. Cross time
is set in seconds (PCU is pre-programmed with 20 seconds as a factory default). Cross time is entered
in 2 digit increments using the numeric keypad. Typical cross time duration is based on pedestrians
walking speed being 2 feet to 3 feet per second. Slower pedestrians require more time than faster
pedestrians. A generic formula to compute a typical cross time is to divide the length of the crosswalk
(width of the street) by either 2 or 3. Cross time should be set by the installer after observing
pedestrian patterns.
An example of a 60 foot long crosswalk: 60’ ÷ 2’ per second = 30 seconds
FACTORY SETTINGS - The system is preset with a cross time of 20 seconds, the activation counts are
set to Zero, & the date/time are set for PST, system default is Single Zone Mode.
ACTIVATION COUNT DISPLAY - When the system is in Activation Count Display Mode (LCD shows
the number of activations for either bollards or push buttons), the system is in “a sleep state”. System
activation WILL NOT occur (IRWL will not operate) until the activation count display mode is toggled off
by pressing either 1 or 3 on the keypad respectively (software version 1.4 & earlier). When using
software version 1.5 & later, activation count display mode will end after 1 minute to allow normal
operation.
DOWNLOADING PCU MEMORY – PCU memory contains a limited number (approximately 65,000) of
“date/time stamped” activation counts, diagnostics, & “power-up” events. The data is accessible using
a computer connected to the appropriate port via RS232. Refer to addendum procedure for correct
steps. This feature is available in software version 1.5 & higher.
SYSTEM ACTIVATION DISPLAY – When the system has been activated, the LCD will indicate a
countdown of the remaining cross time until the Enlighten1TM flashing sequence ends. This feature is
compatible with software version 1.6.7 and higher.
REMOTE COMMUNICATIONS – The PCU is designed for remote communication via the RS232 port.
When operated in Terminal Mode, the remote terminal will echo many of the PCU LCD commands and
text as well as some system diagnostics. Also while in Terminal Mode, the remote terminal keyboard
will operate all of the PCU keypad functions. Refer to addendum procedure for remote connections.
This feature is compatible with software version 1.7 and higher.
SINGLE/DUAL ZONE MODE– The PCU is capable of supporting both Single & Dual Zone Modes
(whether or not the peripheral hardware for the Dual Zone Mode is physically connected to the PCU).
The system default on “power up” is Single Zone Mode. Each time power is recycled to the PCU, the
system will revert to Single Zone Mode operation. If Dual Zone Mode is required, pressing the keypad
2 will toggle into Dual Zone Mode. Single zone can be re-selected either by pressing keypad 2 again or
by cycling power to the PCU. The mode can be verified (displayed on the LCD) using the keypad *.
Refer to Dual Zone Installation Manual Addendum for further information. This feature is available in
software version 1.7 & higher.
Custom functions available only on request
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2.8.3
POWER CONTROL UNIT (PCU) KEYPAD FUNCTIONS TABLE (software v 1.7.X)
Function
Clear all the Counters (Note: manually record counters prior to resetting to zero)
Display number of BOLLARD system activations (for Bollard pairs 1, 2, 3, & 4)
Display number of PUSH BUTTON system activations (for PB’s: A, B, C, & D)
Set Cross Time Enter cross time in 2 digit increments up to 99 seconds.
ZONE 1 - Bollards 1&2 Pushbuttons A&B
Keypad Press
0
→ 555
1
→ # to close
3
→ # to close
ZONE 2 - Bollards 3&4 Pushbuttons C&D
(requires custom PCU and software setting for Single/Dual Zone mode operation)
4
→ 2 DIGITS
7
→ 2 DIGITS
Set Calendar & 3 Scheduled Activations (Auto Time 1, 2, & 3)
5
Set current Time of Day Use 4 digits, i.e. 02:30 (24 HOUR CLOCK)
#
→ 4 DIGITS
#
→ 6 DIGITS
#
→ 1 DIGIT (1 thru 7)
#
→ 4 DIGITS
Set current Date Use 6 digits format mmddyy; i.e. 042903
Set current Day of Week (1 = Sun, 2 = Mon, 3= Tue, etc.)
1st Scheduled Activation
Set Auto Time 1 ON Use 4 digits, i.e. 09:30 (24 HOUR CLOCK)
Set Auto Time 1 OFF Use 4 digits, i.e. 09:40 (24 HOUR CLOCK)
→ 4 DIGITS
Set Days Active press combination of 0 & 1 for each day of the
week SMTWTFS - 0 for inactive day or 1 for active day
→ 7 DIGITS (0 or 1)
2nd Scheduled Activation
Set Auto Time 2 ON Use 4 digits, i.e. 12:30.(24 HOUR CLOCK)
#
→ 4 DIGITS
Set Auto Time 2 OFF Use 4 digits, i.e. 12:40 (24 HOUR CLOCK)
→ 4 DIGITS
Set Days Active press combination of 0 & 1 for each day of the
week SMTWTFS - 0 for inactive day or 1 for active day
→ 7 DIGITS (0 or 1)
3rd Scheduled Activation
Set Auto Time 3 ON Use 4 digits, i.e. 15:30.(24 HOUR CLOCK)
#
→ 4 DIGITS
Set Auto Time 3 OFF Use 4 digits, i.e. 15:40 (24 HOUR CLOCK)
→ 4 DIGITS
Set Days Active press combination of 0 & 1 for each day of the
week SMTWTFS - 0 for inactive day or 1 for active day
→ 7 DIGITS (0 or 1)
Pedestrian Detectors in/out Service
turn power on or off to all Bollards using keypad 6
to alternate between on & off
Single/Dual Zone mode
6
toggles software between single zone and dual zone
modes. The software MUST be in Single Zone mode for
all inputs to activate ZONE ONE.
All Outputs on Constant Blink using keypad 9 to alternate between on & off
2
Display Software Version
*
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2.8.4 POWER CONTROL UNIT (PCU) DETAILED KEYPAD INSTRUCTIONS (software v 1.7)
The following detailed instructions for using the keypad and display is organized by function. The text
on the left describes the key-presses and programming process step, and the text on the right is what is
actually shown on the PCU display.
2.8.4.1
1ST TIME START UP
To activate the system for the 1st time, a start code is required. This start code can be obtained by
contacting LightGuard Systems using the phone number shown in the display.
1st time start up Display
Call 1-888-247-2974
or Enter Start Code:
Key-in the correct 3 digit start code. Keying in the 1st digit will
overwrite the existing display. Each successive digit will overwrite
the previous digit. Example shown is typing in Start Code 123
1
2
3
2.8.4.2
DEFAULT DISPLAY
The Default Display will be visible at all times unless another menu is currently activated. After a short
period of inactivity, the system will generally revert back to the Default Display (exceptions are constant
flash mode & fault conditions) to accept keypad inputs.
The example shown is April 1 2009 @ 9:51A
2.8.4.3
LightGuard Systems
04/01/09
09:51:05
SOFTWARE VERSION
The system will show the software version & zone mode from the internal micro controller.
To display the software version Press *. The example shown is
version 1.7.4 in Single Zone Mode
2.8.4.4
SW version 1.7.4
Single Zone Mode
CHANGE CROSS TIME
The Factory Default Cross Time is set to 20 seconds.
To Set Cross Time for Zone 1, Press 4 to open the menu & then 2
digits to set new time (example 15 sec)
To Set Cross Time for Zone 2, Press 7 to open the menu & then 2
digits to set new time (example 25 sec)
2.8.4.5
Zone 1 Cross Time=20
New Time is 15
Zone 2 Cross Time=20
New Time is 25
CLEAR ALL THE COUNTERS
To Clear all the counters:
press 0 to open the menu
Then press 555
Press 555 to Zero
Counters & Log: ▓
Press 555 to Zero
Counters & Log: 555
Counters are
Set to Zero
Clear counters Message will briefly display
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2.8.4.6
DISPLAY BOLLARD ACTIVATION COUNTS
To Display the number of bollard system activations (bollard pairs
1, 2, 3, 4), press 1 to open the menu. The example shows 12,345
call signals received from each of the bollard pairs.
2.8.4.7
#2= 12345
#4= 12345
#A= 12345
#C= 12345
#B= 12345
#D= 12345
DISPLAY PUSH BUTTON ACTIVATION COUNTS
To Display the number of push button system activations (buttons
A,B,C,D), press 3 to open the menu. The example shows 12,345
call signals received from each of the bollard pairs.
2.8.4.8
#1= 12345
#3= 12345
BOLLARD POWER ON/OFF
The power to the bollards can be toggled off/on using the keypad.
To toggle power off/on to the bollards (both the sensors &
courtesy lights) press 6
To toggle power on/off to the bollards (both the sensors &
courtesy lights) press 6
2.8.4.9
Ped Detectors
OUT OF SERVICE
Ped Detectors
IN SERVICE
CONSTANT FLASH
The flashing outputs can be set to activate continuously.
To set outputs on constant flash, press 9. This message will
display until 9 is pressed again or power is recycled
2.8.4.10
Constant Flash Mode
Press 9 to End
CALENDAR SETTING
The calendar menu is linked / integrated into the auto-time activation feature menu. Once this menu is
initiated, there is no “back” capability. If a mistake is made in keying, either finish the menu sequence &
then repeat the entire process with correct keying or turn the power off/on for system reset. In general,
press * to advance the menu without having to input prompted data.
To set the internal calendar press 5 to open the menu
# = yes / * = no
Set Time? ▓
Press # to enter a new time in 24 hour clock. Example showing
current time 13:11 (1:11 PM)
Example showing current time 13:11 (1:11 PM) changing to 0953
(9:53AM)
Time: 13:11
NEW(24Hr.) ▓
Time: 13:11
NEW(24Hr.) 0953
New Time Message will briefly display
TIME: 09:53
Press # to enter the date
# = yes / * = no
Set Date? ▓
Date: 04/01/09
NEW(MMDDYY) ▓
Date: 04/01/09
NEW(MMDDYY) 010110
Enter the date using 6 digits MMDDYY format
Example showing current date April 1 2009 changing to January
1, 2010
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New Date Message will briefly display
Date: 01/01/10
Press # to enter the day of the week
Example showing current day of the week is Friday changing to
Wednesday
# =
Set
Day
NEW
Day
NEW
New Day Message will briefly display
Day: 4
The AutoTime setting prompt will display. Press * to advance the
menu without setting AutoTime. Press # to set AutoTime.
# = yes / * = no
Set Zone 1 AutoTimes
Enter a number to represent the day of the week using a single
digit 1 through 7
2.8.4.11
yes / * = no
Day? ▓
# is: 6
# (SUN=1) ▓
# is: 6
# (SUN=1) 4
AUTO TIME
After the calendar has been set, the menu will continue for setting up automatic activations at specific
times. This feature is referred to as Auto Time. There are 3 different Auto Time settings available. To
bypass this part of the menu, pressing * will advance thru the successive prompts until the Default
Display is shown. To program the controller for Auto Time, follow the steps below.
Press # to set up Automatic Activations based on schedule. This
example shows how to program the system for Zone 1 activations
from 7:00A-8:30A on Monday Wednesday & Friday. Note that the
same sequence is used for programming Zone 2.
Auto Times Setting Message will briefly display
# = yes / * = no
Set Zone 1 AutoTimes
Zone 1
AutoTime Settings
Then the prompt to Enter a Start Time will display
Time 1 ON: 00:00
NEW Time 1 ON: ▓
Set a Start time for 1st Auto activation to 7:00A
Time 1 ON: 00:00
NEW Time 1 ON: 0700
New Start Time Message will briefly display
Time 1 ON: 0700
Then the prompt to Enter a Stop Time will display
Time 1 OFF: 00:00
NEW Time 1 OFF: ▓
Set a Start time for 1st Auto activation to 8:30A
Time 1 OFF: 00:00
NEW Time 1 OFF: 0830
New On Time Message will briefly display
Time 1 OFF: 0830
Then a prompt will appear to program the days this scheduled
activation will occur.
Days Active1:0000000
NEW SMTWTFS: ▓
Days Active1:0000000
NEW SMTWTFS: 0101010
Keying in a 1 means that auto time is set for that day, a 0 means
no auto time that day. The example shows auto times for Monday
Wednesday & Friday only.
Then a message briefly displays showing the days that have been
set to activate.
Days Active1:0101010
The menu process steps for Auto Time will repeat for EACH of the other 2 auto time activations. These
process steps can also be repeated for Zone 2 as required / if applicable.
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3
IN-ROADWAY WARNING SIGNAL (IRWL)
3.1
GENERAL DESCRIPTION
The LightGuard System® In-Roadway Warning Light (IRWL) LED light fixture is made of a high strength
plastic composite. It is designed for mounting into a base plate assembly that is permanently attached
to the roadway. This allows for any in-roadway warning light fixture that may become damaged, or
inoperable for any reason, to be easily repaired with a plug-in replacement.
IN-ROADWAY WARNING LIGHT (IRWL) TYPE-9X ASSEMBLY
General Performance Specifications
Parameter
Value
Visibility
± 22.5° Horiz
+10° Vert
Operating Temp
−20° to +80°C
Operating Voltage
DC Current @ 12VDC
Avg Power Dissipation
Luminous Intensity
Material
Housing Color
3.2
Typical Mounting
Base Plate Compatibility
SD-10C (composite)
CHS-14 (steel)
Available Models
LGS-9X-1 (Red)
LGS-9X-2 (Amber/Red)
LGS-9X-3 (Amber)
LGS-9X-4 (White)
9VDC to 15VDC
0.1 Amps
1.5 watts
252,000 mcd
Polyurethane/Nylon
Black
MAJOR CONSIDERATIONS FOR LIGHTGUARD SYSTEM IRWL INSTALLATION
There are a number of basic considerations when determining the location and alignment direction of
each in-roadway module for any given installation site. These items should be considered during the
installation procedure for the LightGuard in-roadway warning system. Be sure to have enough specified
wire/cable, 2-part epoxy, and saw cut filler (loop detector type filler) ON SITE BEFORE BEGINNING
INSTALLATION.
Figure 1: Example of properly installed 10”
composite baseplate
Figure 1: Example of properly installed 14”
baseplate in a snowplow region
3.2.1 DISTANCE OUTSIDE OF, AND AWAY FROM CROSSWALK STRIPES
The installer should measure and be certain to keep the distance at least 18” from the outward edge of
the crosswalk. In general, greater distances can be used without any noticeable difference to the
motorist. However, no greater distance than 10 feet (3m) is recommended by MUTCD standards. If
required by a specific circumstance, (i.e., grade or advance curve warning layout) placement may
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necessitate an authorized deviation, using sound engineering judgment (thereby not conforming to
MUTCD standards).
3.2.2 LOCATION OF EACH INDIVIDUAL IRWL MODULE
Each IRWL should be located in a position that will be directionally visible to the approaching motorist
from their viewing position at the wheel usually 200’ to 400’ (61m to 122m) in advance of the crosswalk,
allowing sufficient time to recognize and react to the warning lights upon activation. When locating
IRWL in the path of street sweeping equipment, caution should be taken to consider the proper location
for minimizing possible cosmetic damage to the IRWL at the “curb and gutter” locations (on the
approach sides) by avoiding the “skid paths” associated with this type of equipment.
3.2.3 PATTERN
The pattern or layout should follow the recommended configurations that have been tested and proven
effective for the type of crosswalk for which the system is being used. The MUTCD - Manual for
Uniform Traffic Control Devices 2009 chapter 4N (http://mutcd.fhwa.dot.gov/htm/2009/part4/part4n.htm)
defines the authorized use & application of IRWL. For best practice; one module on the outside travel
lane edge of each parking lane or bike lane (stay out of bike/parking lanes), one module on the center
divider lane or line, and one module in each travel lane approximately under the location of each
vehicle’s license plate, (or centered between the tire paths of the travel lane). The “geographic” center
of the lane may not be the appropriate location as vehicular traffic tends to travel “off center” of any
given marked lane. The idea is to minimize the frequency of tire impact to the in-roadway modules by
placing them outside of the predominant vehicle tire wear pattern. With a raised median strip, the
module that is usually placed on the centerline or lane should be installed on the far left of the approach
lanes next to the raised median curb or barrier. For maximum or higher level needs, an optional
addition of one module on each lane delineation line may be considered. Placement should be in
accordance with MUTCD. Examples showing optional & required placement for California MUTCD can
be found via http://www.dot.ca.gov/hq/traffops/signtech/mutcdsupp/pdf/camutcddraftrev/4L.pdf.
3.2.4 AIMING POINTS
The light beam view path of the modules should be determined by the local traffic engineer or
responsible agency for the purposes of reaching the motorists viewing point 200’to 400’ (61m to 122m)
in advance of the crossing (refer to section 3.7 for aiming and alignment). Generally, the layout
provides for the modules in the approach travel lanes to be aimed straight down the approaching
motorist’s viewing path. The parking lane units (from the left and right sides) should also be aimed or
aligned toward a “control point” approximately 200’ to 400’ (61m to 122m) in advance of the crossing,
and should also converge at the approaching motorist view path. This would have the outside units
canted slightly inward toward the center of the lanes to that point. The units on the center line and
opposing travel lanes will be canted slightly toward the approaching motorist travel lanes to those
“control points” that will allow the approaching motorist the best view of the light source generally from
200’ to 400’ (61m to 122m) away depending upon the approach speeds at the particular location.
Curved approaches will require a greater degree of analysis to provide the maximum benefit.
3.2.5 SAW CUT FOR WIRING AND IRWL MODULES
The saw cut for wiring should follow the manual for depth and width to accommodate the necessary
wiring and tray cable for the installation. As a general rule this averages ⅜”- ½” (9.5mm – 12mm) wide
cut approximately 2 ½” (63mm) deep (should be below core drill depth). Operational component
connections from PCU to across the street can be pulled to terminal boxes for easy access connecting
activation mechanisms and other active LED components using standard type wire. Ensure that the
saw cut makes a complete loop through all IRWL locations (refer to wiring diagram section 3.6.2).
3.2.6 DEPRESSION CUTS FOR LIGHT MODULE (IRWL / SIGNAL HEAD) BASE PLATES
The depression cuts for the base plate assemblies can be accomplished in a number of ways. Most
contractors prefer core drilling or a chip hammer. A flat bottom “Grinding Core Drill Bit” (section 1.7) is
available to improve efficiency. Also, making “cross cuts” in the pavement at the IRWL location will
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considerably expedite the core drilling process (refer to Figure 3 & Figure 4 for example of Grinding
Core Drill & “cross cuts”). After determining the location and aiming direction of a particular light
module, then core or chip out hole approximately 1⅜” ± ⅛” (35mm ± 3mm) deep refer to reference
dimension table 3.2.6.1. A clean “corner” is desired at the bottom (flat bottom, vertical edges). Trim
interior surface to proper depth, clean and prepare for epoxy. The size of the depression cut is VERY
important. If the depression cut is too deep or the OD is too large, then excess epoxy will be required
for securing to the roadway. If the depression cut is too shallow, the base plate will protrude above
grade. If the depression cut OD is too small, insufficient epoxy will prevent the base plate from being
permanently affixed to the roadbed.
Figure 4
Figure 3
3.2.6.1 REFERENCE DIMENSIONS FOR BASE PLATE MOUNTING TO ROADWAY
Base Plate
Model
Base Plate
Material
CHS-14 revH min
SD-10C
Steel
Composite
Base Plate
OD - Outside
Diameter
13¾” (350mm)
9 ⅞” (251mm)
Base
Plate
Height
1⅜” (35mm)
1⅜” (35mm)
Recommended
Depression Cut
Hole Diameter
14” (356mm)
10” (254mm) min
Recommended
Depression
Cut Hole Depth
1½”max (38mm)
1½”max (38mm)
3.2.7 EPOXY
Be sure to have enough wire/cable, SPECIFIED 2 part epoxy (Bondo 7084 Piezo/Traffic Sensor
Sealant available at 800-622-8754 or by LGS upon request), and saw cut filler (loop detector type filler
specified by local regulations) ON SITE BEFORE BEGINNING INSTALLATION. AFTER ALL WIRES
ARE IN PLACE IN THE WIRE CUTS, trim the wire to a suitable length to work with for wiring the base
plates. Using duct seal or equivalent, create a temporary “epoxy dam” section 3.5.3 at the interface
where the saw cuts enter/exit the depression cut area. The temporary epoxy dam prevents epoxy from
flowing from the depression cut into the saw cut.
Remove plastic thread protectors from threaded holes in base plate. Temporarily install socket head
cap screws into threaded holes (approximately 3-4 turns) in order to use the screws for base plate
leveling. Slip the wire through the center hole and “stand” the base plate on end “ready” to place into
the depression. Thoroughly mix the appropriate type of epoxy for use in the base plate depression cut.
Place an appropriate amount of 2 part epoxy in the depression (sufficient to completely seal bottom and
rise around outside edges of the base plate when pushed into place). To insure a proper moisture seal,
place the initial “glob” of epoxy in the center of the depression, move (or wiggle) wires around in the
epoxy to attain wire seal, then push material to the outside edges and set the base assembly in place.
The base plate should be aimed and level (use the temporarily installed screws to elevate the base
plate if required during leveling) before epoxy is allowed to set-up properly. Note: If the depression is
for some reason cut too deep, a “few” small rocks, pebbles or BB’s can be used to maintain a proper
height. It is best to have the epoxy surround the base plate edges approximately level with the surface.
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NOTE: Epoxy working life is approximately 10 minutes depending upon ambient temperature.
After this duration, the base plate can’t be moved. Allow epoxy time to fully set, generally 20 to
30 minutes, prior to installing IRWL.
3.2.8 WIRES
Be certain that wire (ref section 1.6) type RHW-2/USE-2/XLP MAX OD 0.17” (4.3mm) is the correct
size and type for in-roadway modules, and activation mechanisms (bollards &/or Pushbuttons) for
single run across street as recommended. Pull and cut 14 AWG wires to appropriate length. DO NOT
STRIP INSULATION from IRWL wire. Connect to molded plug connector (pigtail cable assembly)
provided in base plate assembly using provided Scotchlok Self-Stripping Pigtail Connectors-crimp to
seal (see section 3.6).
Activation mechanism conductors for push buttons or bollards (should be Belden cable 27601A as
referenced in section 1.6) can be collocated in the same saw cut with the IRWL conductors.
3.2.9 SIGNAL HEAD INSTALLATION
Using compressed air, remove dirt and all debris from base plate cavity. Ensure that mounting screw
threads are clear. For extremely harsh environments, consider placing duct seal or plumbers putty onto
the base plate in the region under the signal head around the outside edge perimeter to minimize the
potential for moisture entering the base plate. Plug pig-tailed base plate cable electrical connector
(RECEPTACLE) into IRWL cable electrical connector (PLUG). Note appropriate alignment for 3 pin
connector. Ensure that mated molded plug connectors are PROPERLY SEATED. Check for proper “O”
ring placement and attach IRWL to base using SOCKET HEAD CAP SCREWS with LOCK WASHERS
and FLAT WASHERS. Tighten using an INCH POUND TORQUE WRENCH.
Composite Base plate: Recommended torque value is not to exceed 4 ft lbs 48 in lbs (5N m) – NO
TIGHTER. Hand tightening with a standard Allen wrench is also acceptable. WARNING – the
composite base plate is very sensitive to this procedure, as damage to the threads may occur if
tightened over 4 ft lbs (5N m).
Check for even contact and snug fit with base plate top surface. Consider placing additional duct seal
or plumbers putty into the gap between the base plate and the signal head and into the counter bore
holes for the socket head cap screws to minimize the potential for moisture or debris from entering the
base plate. Check for LED light module operation and move on to next unit.
NOTE: It is IMPERATIVE that these steps be followed when installing the signal heads. Failure
to do so voids the manufacturer’s warranty. It is highly recommended that within 30-45 days
after initial installation, that the heads be re-checked to verify that the 4 ft lbs (5N m) of torque
has been maintained.
3.2.10 NEW ROAD SURFACE CONSTRUCTION INSTALLATIONS
If site is new construction, conduit under the roadway surface and knockout templates (to achieve base
plate depression excavation for installation) is an option for the installer/contractor. This will avoid or
minimize saw cutting into new roadway surfaces. Plywood cutouts or similar knockouts to match the
base plate assembly size may be utilized in preparation for the installation of the base plates upon
completion of the roadway surface. Precise engineering must to be exercised to insure proper
placement and alignment of the in-roadway modules on the lane lines and travel lanes once the work is
completed. A separate conduit is recommended for the single run of tray cable across the street.
3.3
CONCRETE INSTALLATION PROCEDURE
The following information is a basic guideline for installing LightGuard Systems In-Roadway Warning
Lights at locations where new concrete is to be poured.
Conduit must be installed. It should be placed at least 3" to 4" (76mm to 101mm) below the surface of
the roadway (or as required by local regulations). The single ¾” (19mm) hole in the center of the base
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plate can be enlarged to approx. 2½” (63mm) dia in order to insert two ¾” PVC conduits connected to
90° elbows up into the base plate wiring cavity. Alternatively, a single 1½” to 2" diameter metal or PVC
conduit can be used with a TEE connection stub that extends at least 1" (25mm) above the surface
(after concrete is poured) for pulling wire loops through TEE’s. This is installed at each location where
an In-Roadway Warning Light Base plate will be placed. Minimum recommended conduit is ¾” PVC to
comply with NEC 14AWG type RHW-2/USE-2/XLP conductors.
Use a circular wooden plug or equivalent 1½” (38mm) thick by approx 10⅛" (257mm) dia for SD-10
Base plate or 14" (355mm) dia for CHS-14 Base plate) with a center hole having a diameter just larger
than the conduit stub(s) protruding up from the road bed as a concrete forming tool (ref section 3.2.6.1).
The plug center hole diameter should be minimum 1/8” (3mm) smaller than center hole in base plate to
ensure subsequent base plate seating. The plug is placed over the conduit stub (or elbows) during the
concrete pour to create a depression form for installing the base plate when concrete is dry.
After the concrete is dry, the wooden plug is removed & the base plate is affixed into the road (ref
section 3.2). Excess concrete around the conduit should be removed to allow epoxy to bond the
conduit to the base plate at the center hole. The extended conduit can then be cut flush to the inside
surface of the base plate. Remove any excess epoxy &/or concrete from the base plate. After
conductors are terminated, the exposed portion of the conduit opening should be filled with duct seal to
minimize the potential of moisture or contaminants from entering the conduit.
3.4
IRWL SIGNAL AND BASE PLATE INSTALLATION GUIDELINES
NOTE: Correct Placement of Bases is CRITICAL to System Performance
Step 1 - Determine placement and site angles of in-roadway warning signals to intersect at optimum
driver viewing zone as specified by Signal Alignment Drawing (See Section 3.7.1). Signal assemblies
can be manually aimed, but laser site method is optimal.
Step 2 - Perform saw cuts using pavement cutting device in accordance with predetermined layout to
facilitate hook-ups through bottom of base plate to terminal connection points. Cuts should be ½”
(12mm) wide in accordance with the CA Standard Plan ES-5A, or local standards, with a depth of 2” to
2½” (50mm to 63mm) for direct burial of wire (see Sections 3.5.1 and 3.5.2).
Step 3 - Provide depression cut-out for base plates approximately 1 3/8” (35mm) ± 1/8” (3mm) deep
on concrete or asphalt. Depression cut-out should be ¼” to ½” (6mm to 12mm), slightly larger than
base plate. Depression cut-outs should be level, or even, to conform to the existing approach grade of
the roadway.
Step 4 - If required, dig out for traffic electric hand hole boxes and install boxes for wiring access
points at predetermined locations in accordance with the CA Standard Plan ES-5E, or local standards.
Step 5 - Install all necessary wire to predetermined connection points and lay in cleared roadway cuts.
Using duct seal or equivalent, create a temporary “epoxy dam” section 3.5.3 at the interface where the
saw cuts enter/exit the depression cut area. The epoxy dam will temporarily hold down the wires &
simultaneously dam the core drill area to prevent flow of epoxy back into the saw cut.
Step 6 - Check for proper site distance angles and level depth of base plate (See Sections 3.7, 3.5 and
3.2.4). Mark alignment on roadway for base plate focus direction. Top of base plate (circumferential
edge shown in section 3.5.1) should be flush or slightly below (less than .10” = 2.5mm) roadway
surface AND free from excess adhesive (See section 3.5).
Step 7 - Mix only enough 2-part epoxy (BONDO 7084) for 2 to 3 base plates, since Epoxy working life
is approximately 10 minutes. Surfaces should be cleaned of dirt or debris, and dry before applying
adhesive. Ensure that wires are vertical in the center of the depression cut. Pour epoxy into
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depression cut approximately ¼” (6mm) depth. Pull wire through center hole in base plate. Secure
base plates to roadway surface by pressing the base plate into the epoxy in the depression cut. Ensure
that epoxy flows around the outside diameter of the base plate and slightly around the wires emerging
from the center hole of the base plate, but DOES NOT fill the base plate. Ensure that epoxy fills
outside diameter of base plate up to grade level. Ensure that the base plate is aligned with the mark
made in step 6 above (See section 3.5) and is aimed vertically toward the zone of convergence prior to
epoxy curing. Allow minimum of 30 minutes of epoxy cure time prior to moving wires for connecting
pigtail gel plugs (section. 3.6).
Step 8 - Allow minimum of 1 hour cure time (above 70°F & 2 hours if colder temperatures) before
opening traffic lanes to vehicles travelling over recently epoxied base plates. Signal heads can be
secured to base plates as soon as epoxy has sufficiently hardened. NOTE: Temperature is critical.
Step 9 - Secure in-roadway warning signal to base plates using socket head cap screws using Allen
Wrench or equivalent. Socket head cap screws are to be coated with anti-seize compound for
maintenance purposes to ensure that screws can be removed after exposure to the environment &
additionally contain an embedded nylon thread-lock bead to prevent the screws from backing out while
exposed to the roadway environment.
Step 10 - Complete “dress-up” saw cuts with Loop Sealant etc. DO NOT use Loop Sealant to “dress
up” outside diameter of base plate to level epoxy surface with grade.
3.5
3.5.1
IRWL SAW CUT CROSS-SECTION DIAGRAMS
FRONT VIEW - PARALLEL TO ROADWAY (SD10-C BASE PLATE SHOWN)
IN-ROADWAY WARNING SIGNAL
1½” (38mm)
WIRE
2½” (63mm)
FINISHED GRADE OFPAVEMENT
PAVEMENT
BOTTOM OF
SAWCUT
3.5.2
LOOP SEALANT
EPOXY AROUND BASEPLATE
SIDE VIEW - PERPENDICULAR TO ROADWAY
FINISHED GRADE OF PAVEMENT
DRAWING NOT TO SCALE
In-roadway
warning signal
2 ½” in
MAX.
(63mm)
Eight- conductor
tray cable
(Extra strands
for future use)
.5 in.
In-roadway
warning signal
(12mm)
Loop sealant as approved &
required by public agency
Sand - Gradation 0 - 30
Quarry sand not acceptable
NOTE: USE 14 AWG WIRING, (ref section 1.6.8) APPROVED BY LOCAL AGENCY FOR IN-ROADWAY WARNING SIGNAL ARRAY HOME
RUN CONNECTION. FOR BOLLARD AND PUSH BUTTON’S, ALWAYS USE 8 CONDUCTOR 18 AWG MINIMUM DIRECT BURIAL
CABLE TO ROUTE FROM ENCLOSURE TO OPPOSITE SIDE OF STREET FOR BOLLARD AND PUSH BUTTON’S.
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3.5.3
TOP VIEW (SD-10C BASE PLATE SHOWN)
EPOXY DAM
EPOXY DAM
EPOXY
AROUND
BASEPLATE
WIRING SAWCUT
WITH LOOPSEALANT
14 AWG
WIRES
IN-ROADWAY WARNING SIGNAL
PAVEMENT SURFACE
3.6
TYPICAL IRWL SIGNAL BASE PLATE WIRING DRAWING
Pig Tail GEL PLUG
connectors provided
Base plate cable
connector (PLUG)
14 AWG
Type RHW-2/USE-2/XLP
(YEL, BLK, RED)
in roadway saw-cut
Base plate
Figure 3.6A – Base Plate Wiring (SD-10C shown)
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3.6.1
GEL PLUG TERMINATION INSTRUCTIONS
The Scotchlok 314 Self-Stripping Electrical Pigtail Connectors are moisture resistant and do not require
wire stripping. This can only be done in baseplates that have enough wire extending from the
roadway to allow the IRWL pigtail to set into the underside of the IRWL connector cavity when
assembled. The GEL PLUG connector requires 3/4" (19mm) of wire to be fully inserted into it.
1) Outer Diameter of type RHW-2/USE-2/XLP wire should be MAX OD 0.17” (4.3mm). This will allow
the insulated wire to be inserted into the Scotchlok 314 connector. Any exposed bare wire should
be clipped off from the wires when connected to ensure that no part of the conductor is exposed.
2) Insert all three wires to be connected into the three open holes in the connector, until they all reach
the back end of the connector.
End of Insulated wire should
touch back of connector
3) With a standard pair of slip joint pliers, pinch down on the blue cap of the connector until the outer
edge of the blue cap is flush with the rim of the white connector housing. It may be necessary to
wipe off the expelled gel after crimping.
Flush after crimping
4) Place the connector in the bottom (lowest part) of the base cavity and route the wires so no pinches
will occur when the head is tightened. Double-sided adhesive tape can be used to hold connector in
place until head is re-installed.
5) Plug IRWL into connector and fit IRWL into base. Adjust wires so NO PINCHES occur.
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3.6.2
SAMPLE LIGHTGUARD SYSTEM IRWL DIAGRAM
IN-ROADWAY WARNING SIGNAL,
Typical each side of crosswalk
FACE OF CURB
PUSH TO WALK
BUTTON, Typical
one each side of
street
Note LOOP
for IRWL
connection
LightGuard System™
GUTTER PAN
10 feet,
TYPICAL
CROSSWALK
BOLLARD,
Typical,
one pair
BOLLARD,
each Typical,
side of one pair
streeteach side of
street
WIRING
SAWCUT
SIDEWALK
LED PEDESTRIAN CROSSING SYMBOL
SIGN, Typical each side of street
Refer to section 3.7.1 & 3.7.2 for IRWL Aiming and Alignment
3.7
CONVERGENCE ZONES
The “Zone of Convergence” refers to the area in the lanes of travel where the beams from the inroadway LED lights merge. This “zone” gives the driver adequate time to react to the presence of a
pedestrian by drawing his/her attention to the crosswalk. When aligning signal heads, great care must
be taken to position them correctly to achieve this desired distance.
If the speed limit on the roadway is 25 mph (40Kmh), the “zone” should be approximately 250’ (76m)
out from the signal heads. If the speed limit is 45 mph (72Kmh), signal heads should be aligned to
make the zone 350’ (106m) to 400’ (121m) away from the signal heads. See chart for additional
stopping distances based on road conditions and rate of speed.
Note: Alignment of in-roadway warning signals to be site specific - city engineer or roadway authority
to establish “control points’ for each actual location. Control points may vary depending upon terrain,
slope, vehicle approach speed, or regulation etc.
Chart - Minimum Vehicle Stopping Distance on Dry Pavement
Posted Speed Limit
25 mph (40Kmh)
30 mph (48Kmh)
35 mph (56Kmh)
40 mph (64Kmh)
45 mph (72Kmh)
50 mph (80Kmh)
55 mph (88Kmh)
60 mph (96Kmh)
1 Second Reaction Time
37 feet (11m)
44 feet (13m)
51 feet (15m)
59 feet (18m)
66 feet (20m)
73 feet (22m)
81 feet (25m)
88 feet (27m)
Braking Distance
53 feet (16m)
81 feet (25m)
110 feet (33m)
143 feet (43m)
184 feet (56m)
227 feet (69m)
271 feet (83m)
323 feet (98m)
Page 29
Total Stopping Distance
90 feet (27m)
125 feet (38m)
161 feet (49m)
202 feet (62m)
250 feet (76m)
300 feet (91m)
352 feet (107m)
411 feet (125m)
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LightGuard Systems Installation & User Manual (all rights reserved)
3.7.1
TYPICAL IRWL SIGNAL ALIGNMENT - STRAIGHT ROADWAY
EXAMPLE: TYPICAL FOUR LANE MIDBLOCK CROSSWALK WITH 14 IRWL (DRAWING NOT TO SCALE)
DIRECTION OF TRAVEL
400’ to 200’ (121m to 61m) TYPICAL CONTROL POINTS
DIRECTION OF TRAVEL
400’ to 200’ (121m to 61m) TYPICAL CONTROL POINTS
3.7.2
TYPICAL IRWL SIGNAL ALIGNMENT – CURVED ROADWAY
Determining the location of the “Zone of Convergence” on a curved roadway is similar to a straight
roadway. Using the chart showing the Minimum Stopping Distance on Dry Pavement, determine the
total stopping distance based upon the speed limit of the roadway. The minimum starting point of the
convergence zone is determined by the minimum stopping distance on dry pavement for the posted
speed limit. This minimum stopping distance includes a motorist decision distance, based on a onesecond reaction time, plus the necessary speed deceleration distance required to come to a complete
stop under optimum conditions.
As an example, the minimum stopping distance on dry pavement for a roadway with a 35 mph (56Kmh)
speed limit is approximately 161 ft. (49m). This minimum distance would allow a motorist to visually
recognize the flashing amber LED lights, slow down, and if necessary, bring his/her vehicle to a
complete, safe stop.
Signal heads should be aligned to make the LED lights and therefore the zone appear as soon as
possible as the driver approaches. On curved or winding roads, the entrance to the zone isn’t always
at the optimal distance to provide the earliest possible notification to approaching vehicles. Optional
LED signal heads may also be installed down the center line of the road to give even more advance
warning, giving the driver time to brake and stop for the pedestrian.
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4
4.1
AUTOMATIC ACTIVATION SYSTEM - SMART CROSSWALK™
AUTOMATIC BOLLARD DETECTION SYSTEM DESCRIPTION
Automatic Activation System consists of “gateways” comprised of bollards or posts. Each bollard
contains sensor circuitry, and they are placed so pedestrians entering a crosswalk must pass between
them automatically activating the Smart Crosswalk™. The built-in sensors detect pedestrians using the
crosswalk and detect their direction of travel. The built-in sensor module projects infrared beams of
modulated light to the respective receiver module. Each module incorporates a high gain detector.
This allows the System to activate for Crosswalk entry, and not for exit.
4.2
BOLLARD DRAWING
GRILLED FACE PLATE
covers LED lighting panel
Ball Socket Alignment
Access The Top By
Removing Grilled Face
Plate & Dome Housing
WIRING TERMINAL BLOCK
CONNECTIONS LOCATED
ON BACK SIDE OF PANEL
SPECIFICATIONS
SIZE:
COLOR:
MATERIAL:
DETECTION METHOD:
RATING:
DISTANCE:
OPERATING TEMPERATURE:
Height: 42” (1067mm) Diameter: 8½” (216mm)
White (standard)
Extruded Aluminum Body with Cast Top
Break Beam Modulated at 880 nm
12.5 volts DC (not to exceed 15 V)
Not to Exceed 50 feet between Bollards
-20° C to +70° C Humidity 90% at 50° C (non-condensing)
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4.3.
BOLLARD INSTALLATION GUIDELINES
4.3.1. INSTALLATION STEPS
Step 1 Prior to installing bollards, the proposed site should be inspected several times to observe the
everyday habits of local citizens who utilize the crosswalk. Particular attention should be paid to
how far back pedestrians may “cut the corner” when entering the crosswalk. Bollards, as
positioned, may not detect every pedestrian using the crosswalk. For example, a 12 ft. (3.6m)
wide crosswalk (dimension from outside crosswalk stripe to outside crosswalk stripe), bollards
would be positioned approximately 5 to 6 ft. (1.5m to 1.8m) outside of the outer edge of the
crosswalk stripe and about 18” to 24” (46cm to 61cm) behind the face of curb. Once bollard
locations have been determined, wiring, or conduit, may be run prior to installation of the hold
down bolts (See Section 4.3.2).
Step 2 The preferred method of securing bollards into position is to remove an 8” (20cm) square
section of sidewalk then dig approximately 18” (46cm) and set anchor bolts in 6 sack concrete
mix ( Refer to Bollard Mounting Detail Section 4.3.4). Other methods are acceptable, such as
drilled anchor bolts, however, the bolts may become loose as a result of the bollard being
bumped. A loose bollard will cause the calibrated internal sensors to become misaligned
(reference section 4.5.1 for alignment). J-Bolt alignment template is provided. Snap a “chaulk
line” between bollard pair locations to ensure that j-bolt templates are directly facing each other
(not skewed).
Step 3 After bollard anchor bolts have been set, and the concrete has cured, the bollards can be
secured to the anchor bolts. Position the base of the bollard approximately 1/8” to ¼” (3mm to
6mm) above the finished sidewalk grade, level, and secure. All hardware MUST be tightly
secured. If installed on a sloping sidewalk, ensure that bollard is vertical using leveling nuts.
Step 4 Run wires and make final wiring connections to each bollard (See Section 4.2). Make wiring
connections to terminal blocks in enclosure (See Section 4.3.2). Once wiring connections have
been completed the bollard light sensors are ready to be aligned (See Sections 4.5).
4.3.2
SAMPLE BOLLARD LAYOUT AND WIRING DIAGRAM
Bollard 2-A
NOTE: Always use 8 conductor 18 AWG signal cable for single
run connections between bollards or pushbuttons from enclosure
to opposite side of street (shown as bold dashed line in diagram)
Bollard 1-B
BR BE
AR AE
FROM BOLLARD 2-A TO
2-B, YELLOW, BROWN, &
BLUE WIRING NOT
NEEDED
FROM BOLLARD 1-A
TO 1-B, YELLOW
WIRING NOT NEEDED
AE AR
BE BR
Separate
wider than
crosswalk
ENCLOSURE
NOTE:
Bollard 2-B
AE= A EMITTER & AR= A RECEIVER
BE= B EMITTER & BR= B RECEIVER.
18” MINIMUM
DRAWING NOT TO SCALE
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Bollard 1-A
1-B
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LightGuard Systems Installation & User Manual (all rights reserved)
Refer to section 3.7.1 & 3.7.2 for IRWL Aiming and Alignment
4.3.3
BOLLARD WIRING TERMINAL BLOCK CONNECTIONS
ENCLOSURE TERMINAL BLOCK CONNECTIONS FOR BOLLARDS:
4.3.4
1 1 2 2 P P S S B
A B A B A B + + +
B G G G G
+ N N N N
D D D D
Y
E
L
L
O
W
R
E
D
B
R
O
W
N
B
L
U
E
O
R
A
N
G
E
B
L
A
C
K
BOLLARD MOUNTING DIAGRAM
NOTE
5.5” dia Bolt Circle
Template(3 @ 120°)
furnished by
LightGuard Systems
NOTE: To alleviate wire access or electrical connection
difficulties, conduit height should not exceed 1” above
grade – unless required by local regulations
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4.4
BOLLARD SENSOR ADJUSTMENT
Each bollard is equipped with detection sensors 1 transmitter/emitter and 1 receiver (See Section
4.3.1). To adjust the detection sensors follow the procedure below;
Step 1 Remove upper frosted glass grilled faceplate on bollard 1-A, located near enclosure (See
Section 4.2 & Figure 4-5)
Step 2 Remove 2 counter sunk Allen screws at the bottom of frosted glass opening.
Step 3 Disconnect Brown & Blue terminal block wires from lighted window panel (courtesy light LED).
Step 4 Slide rounded top of bollard (Light Dome Assy) upward and out.
Step 5 Standing behind the bollard, look down 18” (45cm) into the top portion of Bollard 1-A. There are
2 black colored sensor modules. The sensor on the right is the Zone receiver and the sensor
on the left is the Zone emitter (See section 4.3.1 & Figure 4-5).
Step 6 With PCU enclosure door open, observe the 2 rows of Activation LED indicators immediately
below, and slightly to the right of, the PCU keypad (See Section 2.5.1, pg. 8). Starting from left,
to right, the first yellow upper LED is Zone 1A, and the green LED immediately below is Zone
1B, and the second yellow upper LED is Zone 2A, and the second green LED immediately
below is Zone 2B. (Note: some older model PCUs may have all green LED indicators lights).
When one of the Activation LED’s is illuminated, the power control unit (PCU) has been
signaled that an object has entered the activation zone. Once sensor A is triggered, followed by
sensor B, the system is activated for the desired cross time. If an Activation LED is illuminated
but no object has entered the activation zone, then the receiver is not receiving the emitter’s
beam (See note below, this page)
Step 7 Repeat above procedure for bollards 1-B, 2-A, and 2-B. Note that standing behind each
bollard, the emitter is always on left side and receiver is always on right side.
4.5.
BOLLARD ALIGNMENT
After following steps in Section 4.4, if any activation LEDs in the PCU are illuminated, this indicates
bollard detection sensors are out of alignment. To adjust alignment of the bollards refer to Section
4.5.1, and follow the procedure below:
Step 1 - Determine that bollards 1A and 1B are plumb, and aimed directly at each other. If the bollards
are not aimed directly at each other, then align sensors following steps in Section 4.4 above to
compensate for bollard misalignment.
Step 2 - Make sure bollard piezo-electric buzzer at bottom of bollard is temporarily connected with red
wire to + and black to S. If the sensor is not aligned the buzzer will sound.
Step 3 - Ensure there is power to emitting sensor in each bollard, (when standing in behind the bollard
the emitter is on the left side). If there appears to be a power problem, correct then continue.
Step 4 - Adjust a bollard’s receiver and emitter sensors by 1) loosening screws on each side of sensor
and move sensor until piezo buzzer siliences. When properly aligned, each Activation LED indicator in
the PCU will NOT be lit and the piezo will NOT sound which means that both detection zones are clear
and ready for operation. 2) Tighten sensor screws when properly aligned and disconnect piezo. If
Buzzers are not disconnected after alignment, then each time the Bollard Beam is “broken” the buzzer
will sound momentarily. The LightGuard System is supplied with a portable mirror (located in electrical
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cabinet) that can be used to view the LED status Indicators located on the back side of each of the
bollard sensors. (Refer to Figure 4-5). Under normal operation; 1) the emitter/transmitter LED
Status indication will be green, 2) the receiver LED Status Indication will be green only when
partially aligned, both green and orange when perfectly aligned, and yellow only when the light
beam is broken (not receiving signal from emitter). If an LED status Indication is Orange, the sensor is
shorted and requires troubleshooting.
Follow above Steps 1 through 4 for bollards 2A and 2B. Once bollards 2A and 2B are aligned, and
reassembled, ensure that all Activation LED indicators (2 rows of LED’s immediately below the PCU
keypad), are not lit (See Section 2.5). Reassemble the bollards by reversing Steps 1 through 7, of
Section 4.3.1
Emitter
Receiver
Standing behind Bollard & looking Down,
Emitter is on the Left, Receiver is on the Right
Remove Grille, Wires, & Light Dome Assy
LED Status
Indicators
To adjust sensor orientation/alignment, LOOSEN
these screws only, DO NOT remove screws.
Sensor Swivel Mount Assembly (reference only)
Figure 4-5
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4.5.1
BOLLARD ALIGNMENT DRAWING
Example Shown: CROSSWALK ENTRANCE DIRECTION is from LEFT to RIGHT
AR AE
AR AE
AR AE
AR AE
“A” BOLLARD
LIGHT BEAM
ROTATE BOLLARDS TO
DIRECTLY FACE ONE
ANOTHER.
SECURE BASE PLATE
DISTANCE
MAXIMUM
50 FEET
LIGHT BEAM
ROTATE EACH SENSOR
TOWARD CENTER UNTIL
PIEZOELECTRIC BUZZER
CEASES TO EMIT SOUND.
ROTATE SENSORS
OUTWARD TO
MISALIGN
TIGHTEN LOCKING
NUT/SCREW TO
SECURE IN PLACE.
“B” BOLLARD
NOTES:
•
•
•
•
•
•
•
•
4.6.
BE BR
BE BR
BE BR
BE BR
STEP 0
STEP 1
STEP 2
STEP 3
ENTERING THE CROSSWALK, “A” BOLLARD IS ALWAYS ON THE LEFT, “B” BOLLARD IS ALWAYS ON THE RIGHT
WHEN BOLLARDS ARE INSTALLED AT COPLANAR ELEVATION, THEN VERTICAL ALIGNMENT IS INHERENT.
ELEVATION MISALIGNMENT SHOULD BE MINIMIZED
THE SET UP DEPICTED IS AN EXAMPLE OF BOLLARD PAIR ENTERING CROSSWALK FROM THE LEFT
AE= EMITTER INSIDE THE “A” BOLLARD – LOCATED ON LEFT SIDE AS THE CROSSWALK IS ENTERED
AR= RECEIVER INSIDE “A” BOLLARD – LOCATED ON LEFT SIDE AS THE CROSSWALK IS ENTERED
BE= EMITTER INSIDE “B” BOLLARD – LOCATED ON RIGHT SIDE AS THE CROSSWALK IS ENTERED
BR= RECEIVER INSIDE “B” BOLLARD – LOCATED ON RIGHT SIDE AS THE CROSSWALK IS ENTERED
BOLLARD DETECTION ZONE OPERATION
Step 1 Ensure zones are correctly connected to the flashing controller by observing the Activation LED
indicators immediately below the PCU keypad (see Section 2.8.1) or alternatively on the left
side on the ECP.
Step 2 Observe pedestrian entering the crosswalk between the bollards. The first LED that lights
should be yellow (PCU upper row is A zone), the second should be green (PCU lower row is Bzone - lower rows are green in some PCUs). If the LED’s illuminate in the reverse order, then
the wires are reversed. To correct, reverse wires 1A and 1B at the PCU terminal block
connections.
Step 3 Observe pedestrian exiting the crosswalk. The activation LED indicators should light in order of
Zone 2B, then Zone 2A. In this condition, the PCU will ignore the call signal and not initiate the
flashing sequence.
Step 4 Observe pedestrian returning from other side of street entering the crosswalk between bollards
2A and 2B. Ensure that when pedestrian enters the crosswalk between bollards that the 2A
Activation LED (yellow) comes on, then the 2B Activation LED (green) comes on.
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4.7
UNI-BOLLARD / ISAD INSTALLATION OPTION
The Uni-Bollard is a similar to the standard Bollard. Both contain a courtesy light. The difference
between the standard Bollard and the Uni-Bollard is that the Uni-Bollard contains 2 receivers instead of
a receiver/transmitter pair. The Uni-Bollard is designed to be installed with an ISAD (which contains at
least 1 broad beam width transmitter). Each Uni-Bollard is required to have 4 conductors – (1) 12VDC,
(2) Switch wires, & (1) ground. The switch wires are terminated in the control panel in the manner
described in section 4.3.2.
Access to the Uni-Bollard sensors is identical to the procedure noted in section 4.2. Electrical
connections are made to clearly marked terminal posts located inside the Uni-Bollard
The ISAD installs in the pavement in the identical manner as an In-Roadway Warning Signal shown in
section 3. The recommended maximum distance between the Uni-Bollard & the ISAD for reliable
operation is 25 ft. (7m).
4.7.1
UNI-BOLLARD CONFIGURATION DIAGRAM
Uni-Bollard Sensor Locations
Infrared Light Beams
WIRING TO CONTROLLER
WIRING BETWEEN ISAD & UNIBOLLARD
ISAD
FOCUS PARALLEL
to BOLLARD FACE
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4.7.2
EXAMPLE UNI-BOLLARD INSTALLATION DIAGRAM
Typical Uni-Bollard installations are arranged with an ISAD installed in the roadway & a Uni-Bollard
installed on the sidewalk. The drawing below depicts example locations for field installation.
4.7.3
•
•
•
•
ISAD PLACEMENT & CONSIDERATIONS
The ISAD should not be placed such that Direct Sunlight is focused into the face of the ISAD.
This could degrade activation reliability
The ISAD should not be placed in the roadway such that debris or Water can “build up” on the
face. This will cause excessive field maintenance.
The ISAD should be placed relatively close to the curb (not in the flow of traffic). If the ISAD is
placed in the flow of traffic, this will induce nuisance (false) activations of the crosswalk warning
system.
The ISAD must be oriented such that it is facing directly parallel to the Uni-Bollard (refer to
figure in section 4.7.1) & is relatively level with the roadway. However the ISAD may require
tilting to ensure that the transmitters in the ISAD are pointed at the Uni-bollard sensor locations.
The Uni-Bollard sensors are used to effect the ISAD alignment.
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4.7.4
UNI-BOLLARD WIRING DIAGRAM
The following diagram illustrates how to connect a Uni-Bollard & ISAD to the LGS controller cabinet.
The ISAD is powered from the B+ and GND terminals. The crosswalk entrance side of the Uni-Bollard
is connected to either 1A or 2A. The crosswalk exit side of the Uni-Bollard is connected to either 1B or
2B.
4.7.5
UNI-BOLLARD SENSOR ADJUSTMENT
The ISAD cannot be adjusted in the field. Only the Uni-Bollard can be aligned to the ISAD after
installation. The Uni-Bollard sensors are adjusted as described in section 4.4. The audible buzzer in
the Uni-Bollard is attached to one sensor for alignment & then subsequently disconnected. The audible
buzzer is then attached to the other sensor for alignment & then subsequently disconnected.
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5
5.1
PUSH BUTTON ACTIVATION
MANUAL PUSH BUTTON ACTIVATION DESCRIPTION
Manual installations utilize a standard pedestrian operated push button assembly to activate the
system. In these installations, a pole mounted control box containing the push button, a small sign with
the words “CROSS WITH CAUTION”, and a row of 4 flashing amber LEDs, as shown below, is placed
near the entrance to crosswalk (refer to section 3.6.2). The row of 4 flashing, amber, LEDs indicates to
the pedestrian the warning system is activated. The words “CROSS WITH CAUTION” remind the
pedestrian to maintain vigilance for their own safety by paying attention to traffic conditions while
crossing the street. This standard pedestrian activation push button device should be installed as
recommended in the Manual on Uniform Traffic Control Devices (MUTCD) or other local agency
approved specifications.
5.2
ILLUMINATED PUSH BUTTON ASSEMBLY
GENERAL SPECIFICATIONS
ASSEMBLY SIZE:
COLOR:
FACEPLATE LIGHTS:
MATERIAL:
VOLTAGE:
MOUNTING:
5.3
Height: 11¾” (300mm) - Width: 5” (127mm)
Green housing, yellow/black faceplate, silver tone 2 inch push button
Amber Light Emitting Diodes (LEDs) which flash with system activation
Cast Aluminum
12.5 volts DC (not to exceed 15 V)
See local agency approved standard specifications for location and height
SAMPLE PUSH BUTTON LAYOUT AND WIRING DIAGRAM
LightGuard System™
GUTTER PAN
IN-ROADWAY WARNING SIGNAL,
Typical each side of crosswalk
FACE OF CURB
PUSH TO WALK
BUTTON, Typical
one each side of
street
10 feet,
TYPICAL
ENCLOSURE
CROSSWALK
BOLLARD,
Typical, one pair
each side of
street
WIRING
SAWCUT
SIDEWALK
LED PEDESTRIAN CROSSING SYMBOL
SIGN, Typical each side of street
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5.3.1
PUSH BUTTON WIRING TERMINAL BLOCK CONNECTIONS
CABINET TERMINAL BLOCK CONNECTIONS FOR
PUSH BUTTONS:
5.4
1
1
2
2
P P S S B
B G G G G
A
B
A
B
A B
+
+
C
O
L
O
R
R
E
D
C
O
L
O
R
+
+
N
N
N
N
D D D D
B
L
A
C
K
PUSH BUTTON INSTALLATION DETAIL DRAWING
Follow instructions noted on drawing for pole mounting & wiring detail.
Mounting bolt holes must be tapped in pole. Wire access holes should
be de-burred to prevent wire insulation damage. Conductors between
LED placard cavity & Push Button cavity MUST be routed INSIDE
the pole to ensure weather tight integrity.
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6
LED “ENHANCED” ILLUMINATED WARNING SIGNS
6.1
LED “ENHANCED” SIGN GENERAL DESCRIPTION
LightGuard System® installations may, as an option, utilize fluorescent-yellow-green (FYG) color,
diamond shaped pedestrian crossing symbol signs (W54, W11A-2, W-11-2, W-54-A or equivalent),
equipped with flashing amber LED modules located below the walking pedestrian symbol (See below).
These signs are placed at, or before, the crosswalk to assist in warning approaching motorists that a
pedestrian is in, or about to enter the crosswalk. The embedded LED modules flash at the LightGuard
System® enhanced flash rate. This LED “enhanced” pedestrian crossing symbol sign should be
installed at the crosswalk location as recommended in the Manual on Uniform Traffic Control Devices
(MUTCD) to replace the standard yellow W54 sign. For school crossings, a W66 or W-63 type (S2-1 or
S-2-1 in FYG) school symbol sign also available. NOTE: Any advance warning signs should be
consistent with color of other signs.
6.2
LED “ENHANCED” PEDESTRIAN CROSSING SIGN DRAWING
FLASHING AMBERLED LIGHT
MODULES
(operational when system is active)
NOTE: LightGuard
recommends
NOTE:
This LED enhanced
sign
that this only
LED enhanced
should
be used insign should
be used in conjunction
with an inconjunction
with an in-roadway
roadway
LightGuard
System™
LightGuard System™
installation.
JAN-2001 – New MUTCD
changes sign to W11-2
ONLY (without striping
under pedestrian symbol)
installation. Stand alone
DRAWING NOT TO SCALE
ACTIVE PEDESTRIAN CROSSING SYMBOL SIGN WITH LED MODULES
SPECIFICATIONS
SIZE:
TYPE:
COLOR:
FACEPLATE LIGHTS:
VOLTAGE:
MOUNTING:
30” x 30” (76cm x 76cm)
Standard configurations: W-54, W-54A, W-63, W-66, W-79, R-1, W-47,
W-11A-2, W11-2, S-1-1, S-2-1, W-11-1, W-11A-1, R-1-1, W-10-1
Custom configurations available upon request
Standard fluorescent -yellow-green. Optional high intensity yellow
Amber Light Emitting Diodes (LEDs) which flash with system activation
12.5 volts DC (not to exceed 15 V)
Bracket assembly provided (tamper resistant fasten hardware to be
supplied by installer) See local agency approved standard specifications
for location and height
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7
7.1
1.
2.
3.
4.
5.
6.
7.2
LIGHTGUARD SYSTEMS SOLAR POWER OPTION
INSTALLATION STEPS
Using the drawing, assemble the Solar Panel mount with the hardware supplied.
Use the ¼” hardware to attach the module to the Module Rails.
Use the 5/16” hardware to bolt the Module Rails to the SPM-1 Pole Bracket.
Adjust the mount to the proper tilt angle for your site latitude.
Face the solar module due South (NOT MAGNETIC SOUTH) for Northern Latitudes and due
North for Southern Latitudes.
ENSURE that the Batteries are fully charged prior to installation.
SOLAR MODULE
Use the 14 / 2 TC tray cable supplied to wire the solar module into the charge control panel inside the
enclosure. It is recommended that ½” flexible metal conduit be run between the solar module junction
box and the mast to protect the tray cable. An opening in the mast to accept the conduit will need to be
provided.
Remove the cover of the black junction box on the back of the module and note the 6 screws. Also,
note a positive (+) sign and a negative (-) sign which show the 2 positive and negative terminals.
Connect 1 wire to either of the 2 positive (+) and negative (-) terminals. Use the red conductor for
positive and the black for negative. Do not use either of the 2 screws in the middle, these screws are
not electrically connected to the module circuit.
Route the tray cable down the mast into the enclosure. Make sure the solar module is covered, or not
connected to the tray cable, when routing the cable through the enclosure. Even in low sunlight the
module can produce 18 to 20 volts.
7.2.1
SOLAR MODULE DESCRIPTION
The solar array consists of a minimum 75 watt solar power module which is to be pole mounted. This
solar module is designed to charge the two 12 volt batteries in the system. In full sun, this module can
produce a maximum on 4.25 amps when charging the battery. During the day, the amount of charging
current will vary with the intensity of the sunlight hitting the module. The open circuit voltage (voltage
when not connected to charging circuit) can be up to 21 volts.
7.2.2
SOLAR MODULE MOUNTING
The solar module is to be mounted to the side of a 4” galvanized mast using the aluminum side-of-pole
mount and hardware supplied. The solar module must be oriented facing TRUE South . Attach the
mounting rails to the pole bracket and adjust the tilt angle to create an angle setting for your local
latitude from horizontal facing South. Refer to sections 7.2.3 & 7.2.4 for orientation details. Use U-bolts
to secure the mount to the mast
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Instructions for SOLAR PANEL MOUNT, model #HPMH-50/90, side-of-pole mounting kit:
PARTS LIST
Part
Qty
SPM-1
Module Rail
1/4-20X3/4” SS Bolt
1/4-20 SS Flat Washer
1/4-20 SS Lock Washer
1/4-20 SS Nut
5/16-18 x 1” SS Bolt
5/16-18 SS Flat Washer
5/16-18 SS Lock Washer
5/16-18 SS Nut
4” Hose Clamp
4” U-Bolt
1
2
4
4
4
4
4
8
4
4
2
1
Solar Panel Terminal Block
Electrical Connections:
POSITIVE to Terminal 0
NEGATIVE to Terminal 6
7.2.3
ORIENTING THE SOLAR MODULE
The following information was authored by www.powerupco.com & is reprinted herein without permission
It is important for proper system operation that the array be oriented true South (if you are located in the
northern hemisphere). The directions of magnetic South and true South differ from one another
depending on geographic location. This variance is called declination. Check the deviation for your
region in order to extrapolate true South from a compass heading of magnetic South. The map in this
section shows the magnetic declination for the US. For example, central Oklahoma falls between the
8° E and the 10° E lines. This means that the north point of a compass points about 9° E of true north.
So true north is actually 9° to the WEST of where the compass points
7.2.4
DECLINATION ANGLE FOR SOLAR PANELS
The following information was authored by http://www.oksolar.com/ and is reprinted herein without permission
When installing photovoltaic modules, be aware that they generate maximum power when facing the
sun directly. The fixed position which approximates this ideal over the course of the year, thus
maximizing annual energy production, is facing due South (in the Northern Hemisphere) or due North
(in the Southern Hemisphere) at the angle listed in the table in the next column. Note that these
orientations are true, The table below shows the fixed angle above horizontal at which modules should
be installed in order to maximize annual energy output.
At some installations, it may be cost-effective to adjust the tilt seasonally. At most latitudes,
performance can be improved during the summer by using an angle flatter than the chart’s
recommendation; conversely, a steeper angle can improve winter performance.
If modules are not cleaned regularly, it is recommended that they not be mounted at an angle flatter
than 15°. Flatter angles cannot take full advantage of the cleansing action of rainfall.
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7.2.5 MODULE TILT ANGLE
Solar modules produce the most power when they are pointed directly at the sun. For installations
where the solar modules are mounted to a permanent structure, the solar modules should be tilted for
optimum winter performance. As a rule, if the system power production is adequate in the winter, it will
be satisfactory during the rest of the year. The module tilt angle is measured between the solar
modules and the ground.
Example: A module mounted in Miami, Florida (latitude 26º should be tilted at approximately 31º from horizontal, and should be faced due South.
Latitude
Site
0-15°
15-25°
25-30°
30-35°
35-40°
40° +
7.3
Tilt Angle
15º
SAME AS Latitude
add 5° to local latitude
add 10° to local latitude
add 15° to local latitude
add 20° to local latitude
SOLAR SYSTEM BATTERIES
The enclosure contains 2 SLA batteries, the PCU (power control unit) and the charge controller. Two 12
volt deep cycle sealed gel-cell batteries are supplied. Each battery is rated at approximately 100 amp
hours. The batteries are to be wired in parallel (positive-to-positive and negative-to-negative) to give 12
volts nominal at 200 amp hours of storage. Use the red and black battery cables supplied to parallel the
batteries. Install the wiring into the terminal blocks & circuit breaker before installing the batteries.
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Use the red and black cables, supplied with the ring terminals, to make the battery connections.
Connect the red cable to the positive post on 1 battery and the black cable to the negative post on the
other battery. This will ensure even charging between the 2 batteries (note figure below).
+
-
Battery 1
Battery 2
Connect the red and black #14 tray cable wires, from the solar module, to the labeled circuit breaker and
negative buss block (refer to Section 2.4.3).
7.4
7.4.1
CHARGE CONTROLER
CHARGE CONTROLLER WIRING
The charge controller, located inside the enclosure, provides all wiring connections for the solar module,
batteries, and power to the PCU. The PCU controls power to the in-roadway warning signals, signs, and
push buttons.
Ensure all circuit breakers are OFF before making any connections. There are three 15 amp circuit
breakers:
1)
2)
3)
7.4.2
Solar Module circuit breaker; controls power from the solar module.
Load circuit breaker; controls load power to the PCU, in-roadway warning signals, and signs.
Battery Main circuit breaker; controls battery power to the system.
SOLAR CONTROLLER
A charge / load controller is located on the charge control panel (for further information / specs, contact
your LGS representative). This controller is being used to regulate the battery charging and protect the
batteries from being over discharged. The charge controller is pre-wired and factory adjusted. Do not
make any adjustments to the charge controller without contacting LightGuard Systems, Inc. first.
Indicator(s) on the face of the controller indicates the battery state of charge. Note the legend on the
face of the charge controller.
During normal operation, the charge controller will allow the battery voltage to rise up the approximately
14.1 volts while charging. This end-of-charge voltage will vary with temperature. The charge controller
might employ a supplemental temperature probe attached to the side of one of the batteries in the
enclosure. If supplied, attach the probe approximately three quarters of the way up the side of the
battery case using the adhesive pad on the probe. This will ensure proper charging of the batteries
throughout the year.
At night, the battery voltage should register between 12.0 and 12.8 volts depending upon how well the
batteries were charge during the day. In times of exceptionally bad weather, and / or exceptionally
heavy crosswalk usage, the battery voltage may drop below 12.0 volts. When the voltage drops to
below approximately 11.8 volts, the charge controller will shut off power to the PCU and in-roadway
warning signals ensuring protection of the batteries from damage as a result of over discharge. The
charge controller will not allow power back to the PCU until the voltage rises back up to approximately
12.8 volts after several hours of charging. This solar power system is designed to operate in all
weather conditions throughout the year.
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A copy of the Charge Controller Owners Manual is available upon request.
8
TROUBLE SHOOTING / MAINTENANCE / AFTER INSTALLATION
8.1
TROUBLE SHOOTING GUIDE
SYMPTOM
CHECK
ACTION
SYSTEM WILL NOT
ACTIVATE
Check PCU for proper System
operation by "PUSH TO TEST"
Button on right side of PCU
If LED Activation Indicator flashes, Check bollards for proper
alignment and sensors shields for obstruction. Check push buttons
connections. If LED Indicator does not flash, check PCU
components.
Check all in-roadway warning
signals for damage
Remove & Replace (R & R) with spare warning signal as needed.
Check all in-roadway warning
signal window ramps for
blockage or debris.
Broom any debris from pavement around in-roadway warning
signals to allow for unobstructed motorist viewability.
Check all in-roadway warning
signal light modules for proper
flash operation
View in-roadway warning signals from 150' to 200' away for the
approaching motorists' perspective.R & R with spare warning signal
as needed.
Insure that enclosure
components are operational
Shut off power to PCU via circuit breakers and disconnect battery.
Check battery voltage. Load test battery 3-4 AMP. Tighten wire
connections, and/or remove, and look for corrosion and retighten.
Perform a wire push/pull test to verify wires are firmly installed.
Power up PCU with battery only. Check voltage at battery to assure
that battery has minimum of 12.5 Volts. Document counters and log
date, time of service, and name of personnel repairs. List any
repair findings. Secure system door.
GRAFFITI OR PAINT ON
BOLLARDS OR ENCLOSURE
EQUIPMENT
Check for proper activation
operation
Remove graffiti or paint. Tagster Graffiti Emulsifier from Rhomar
Industries is recommended. Call (800) 688-6221to order.
SYSTEM ON CONSTANT
BLINK * PCU FLASHING
50/50
Check for stuck PB or misAligned Bollards ref section 4.4
PUSH BUTTON INPUTS DO
NOT ACTIVATE FLASHING
OUTPUT
Verify that button(s) is/are
operational.
Verify conductor integrity from
push buttons to flashing
controller
IN-ROADWAY WARNING
SIGNALS FLASHING DIMLY,
OR NOT AT ALL
•
•
•
•
•
•
•
•
•
Inspect PCU display for diagnostic information. System enters
“Default Flash Pattern” to alert maintenance crews that attention is
required. If the LCD does not indicate which input is “stuck”, then
press “D” on the keypad to display input diagnostics.
Inputs can be simulated at the flashing controller. Temporarily
remove the button input field wires from the Din Rail locations
PA/PB& affix a jumper wire (12” stripped ½” at both ends) into the
DC GROUND on the Din Rail. Then use the “free end” of the
jumper to make contact with the PA/PB inputs on the flashing
controller. If an LED indicator illuminates, then the PCU can receive
signals & the problem is with the field wiring or the Push Button(s)
Routine maintenance should include periodic on-site inspections of the System for proper operation.
Check activation system for proper operation and tighten fastening hardware as needed.
Clean bollards and sensor shield if needed and check for proper bollard alignment and activation.
In-roadway warning signals should be visually checked for sufficient light output with window ramps
swiped clean as needed. Should window ramp become obscured over time, remove and replace
with spare warning signal.
Check for proper adhesion of all warning signals to the roadway surface. Fill any gaps around inroadway signal assemblies with bituminous hot stick to prevent debris or moisture intrusion.
Inspect wire trench cuts for sufficient loop sealant and fill where needed with filler or bituminous hot
stick material.
Check enclosure and sign mounts for secure attachment and tighten fastening hardware as needed.
Note/Record activation counts using PCU keypad functions 1, 2, or 3, then reset to clear by pressing
0, then 555 (NOT MANDITORY)
Note and clean any graffiti from enclosure equipment. (We recommend Tagster™ Graffiti Emulsifier
from Rhomar Industries - Springfield, Missouri - (800) 688-6221 - Email: [email protected])
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8.2
FIELD RELATED TOTAL PREVENTATIVE MAINTENANCE
After initial installation, the following steps should be followed to test/validate correct operation and to
ensure proper operation in the future. Installation should consist of all components secured
appropriately and all electrical connections terminated as required.
Step 1 Energize all circuit breakers
Step 2 Contact LightGuard Systems to obtain a 3 digit ACTIVATION CODE for warranty &
maintenance tracking purposes. (888) 247-2974
Step 3 Verify that no LED fault/activation indicators are ON in the PCU. These indicators are 2 rows of
LED (Yellow & Green) directly below the PCU housing in the enclosure. If any fault/activation
indicators are on, check Bollard alignment, push buttons, and field wiring connections.
Step 4 Press keypad 9 to initiate constant blink. Verify that all IRWL & optional illuminated LED signs
& Push Buttons are active
Step 5 Press keypad 9 to toggle constant blink off
Step 6 Test/verify that activation mechanisms operate (PB &/or Bollards) and activate flashing output
for the cross time duration. If any Bollards activate the system when exiting the crosswalk
instead of entering the crosswalk, swap A & B wires in control panel for that Bollard pair.
Step 7 Set cross time as required (refer to section 2.8.3)
8.3
FIELD RELATED TOTAL PREVENTATIVE MAINTENANCE
8.3.1
SCOPE
This procedure describes the recommended process for inspecting & maintaining LGS equipment after
installation. This section applies to Illuminated signs, electrical interface cabinets, In Roadway Warning Lights
(IRWL), and activation mechanisms (Bollards & Push Buttons).
8.3.2
MAINTENANCE PERIOD
Perform Preventative Maintenance/Inspection approximately every 6 months.
8.3.3
MATERIAL REQUIRED
A. Battery tester
B. Non-Metallic Whisk broom
C. Soapy water and cloth
8.3.4
RECOMMENDED SPARES
A. IRWL
8.3.5
ELECTRICAL INTERFACE CABINET (AC, SOLAR, ECP)
1.
2.
3.
4.
Open Electrical Interface cabinet
Clean any foreign matter that might have accumulated inside cabinet, (spider webs etc.)
Test battery voltage, if value is less than 12VDC refer to trouble shooting guide (section 8.1)
Optional activation data, (consider posting on inside cabinet door for recordation review).
a. use keypad 1 & 3 to display activation history, record activation data (date & number of
activations) on paper and store in LGS enclosure
b. reset activation counters using keypad 0, then 555 to clear activation history
5. Press keypad 9 to verify that all light outputs activate, press 9 again to toggle outputs back to ready mode
6. SOLAR powered systems
a. If solar panel has foreign matter on it, clean solar panel using water
b. Verify that the charge controller indicates that the batteries are being charged & warranty period
(date) on batteries is valid
8.3.6
ILLUMINATED SIGNS
1. Verify that light windows in illuminated signs are clear of debris, and properly aligned to target path, and
all LED modules operate fully.
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8.3.7
ACTIVATION MECHANISMS
1. Push buttons
a. verify that LED lenses on push button placards are clear of debris
b. verify that push buttons activate flash sequence (Four LED indicators each sign)
2. Bollards
c. Verify that Bollards are aligned (indicated by Electrical Interface Panel LED’s LD1 through LD12
are all NOT illuminated)
d. Verify that Bollard courtesy lights are illuminated (refer to section 4.3)
e. Ensure that Bollard sensors are clean with no obstructions inhibiting sensor performance
f. Ensure that Bollards are SOLIDLY secure to mounting pads by attempting to “rock them”
8.3.8
IRWL
1. Verify that all IRWL illuminate when system is activated
a. if any IRWL do not activate, refer to troubleshooting guide in LGS Installation Manual
2. Verify “self clearing” design is keeping debris build-up clear from front of units, (If needed wipe window
with wet cloth).
3. Within 60-90 days of Initial installation, verify that each IRWL is secure/seated in base plate. If loose,
then remove IRWL, clean mating surfaces, and reinstall in accordance with LGS Installation Manual.
Repeat at 6 month intervals.
4. If any IRWL are broken, then replace units
5. Inspect IRWL for signs of condensation. If from approximately 200 feet this presents a noticeable
decrease in performance or signal head visibility, it should be replaced. If condition does not appear to
affect the light visible to the motorist, it may not need replacement (review warranty in T’s & C’s).
8.4
EQUIPMENT LIST
This section describes standard components of the LightGuard family of products applicable to this
Installation Manual.
8.4.1 SPARES & REPLACEMENTS EQUIPMENT LIST
The following list contains LGS model names/numbers for items typically sold as spares or
replacements.
ITEM
DESCRIPTION
LGS-SN-LED
LGS-BOL SENS ASSY
LGS-GEL-PLUGS
LGS-ORING
LGS-PB ONLY
LGS-GRAYHILL RELAY
LGS-CDMRLY
LGS-9X-1
LGS-9X-2
LGS-9X-3
LGS-9X-4
LGS-CHS 14
LGS-PCU-MICRO
LGS-SD10-C-FG
Amber LED module for illuminated signs
T3 bollard sensor assembly – RCVR, XMTR, swivel mount, bracket
IRWL electrical splice connection inside base plate
IRWL sealing oring
Push button mechanism
Magnecraft relay for obsolete back panel
Crydom relay for obsolete back panel
Signal head only - red LED
Signal head only - bi-color red/amber LED
Signal head only - amber LED
Signal head only - white LED
Base plate only - 14" snowplow resistant
Lgs-micro controller module for PCU
Base plate only - 10" composite
LGS-SOL-PANEL-ONLY
Solar panel for LGS 2' x 4' (80 watts)
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8.4.2 STANDARD EQUIPMENT LIST
The following list contains LGS model names/numbers for Standard items applicable to this Manual.
ITEM
LGS-SOLAR SYSTEM
LGS-SOLAR SYS-DUAL ZONE
LGS-ECP-1
LGS-ECP-2
LGS-PCU/A DUAL
LGS-PCU/BKPN-AC
LGS-PCU-AC
LGS-9X-3/CHS-14
LGS-9X-3/SD10-C
LGS-9X-1/CHS-14
LGS-9X-1/SD10-C
LGS-9X-2/CHS-14
LGS-9X-2/SD10-C
LGS-PBA-BRAILLE
LGS-PBA-PAIR
LGS-PBA-POL-PAIR
LGS-ISAD/UNIBOLLARD-SET
LGS-RAD
LGS-T3
LGS-W11-8
LGS-W16-7P
LGS-W47
LGS-W54/W-11A-2
LGS-W54-A/W11-2
LGS-W54-A/W11-2-B
LGS-W54-A/W11A-2-B
LGS-W63/S-1-1
LGS-W63/S-1-1-B
LGS-W66/S-2-1
LGS-W66/S-2-1-B
LGS-W79/W-11-1
LGS-ISAD
LGS-T3I
LGS-BONDO
LGS-CAB-SOL
LGS-PCU-ASSEMBLY
LGS-AC BEACON-KIT
LGS-AC-OUT-UPGRD
LGS-DC BEACON-KIT
LGS-DC-OUT-UPGD
LGS-NOVAX-UPGD
9
DESCRIPTION
Solar Powered PCU w/Programmable Interface, Batteries, Cabinet & Panel
Solar System with Dual Independent Zone Upgrade
Entry Level LGS Control Panel and Cabinet
Entry Level LGS Control Panel - custom applications only
Dual Zone A/C PCU w/ Battery Backup & Programmable Interface, Cabinet
AC Power Control Unit w/Backpan, Battery Backup & Programmable Interface Only
Standard A/C PCU w/Programmable Interface, Battery. Backup, Backpan & Cabinet
Amber LED Signal Head w/ Snow Plow Resistant 14"Base Plate
Amber LED Signal Head w/ 10" Composite Base Plate
Red LED Signal Head w/ Snow Plow Resistant 14"Base Plate
Red LED Signal Head w/ 10" Composite Base Plate
Bi-Color LED Signal Head w/ Snow Plow Resistant 14"Base Plate
Bi-Color LED Signal Head w/ 10" Composite Base Plate
ADA 2" Push Button Assembly w/ Braille Placard- Pair
ADA 2" Push Button Assembly w/LED Placard - Pair (L & R)
ADA 2" Push Button Assembly w/LED Placard & Audible Message-Pair
In Surface Unit & Automatic Pedestrian Detection Bollard Activation (set)
Remote Activation Detector
Automatic Pedestrian Detection Bollard
Fire Station Sign & LED Enhanced Symbol
Arrow Sign
Highway Rail grade Crossing Sign & LED Enhanced Symbol
Ped Sign w/ Crosswalk Lines & LED Enhanced Symbol
Ped Sign w/out Crosswalk Lines & LED Enhanced Symbol
Ped Sign w/ Crosswalk Lines & LED Enhanced Border
Ped Sign w/o Crosswalk & LED Enhanced Border
School Sign w/ Crosswalk Lines & LED Enhanced Symbol
School Sign w/ Crosswalk & LED Enhanced Border
School Sign w/out Crosswalk Lines & LED Enhanced Symbol
School Sign w/o Crosswalk & LED Enhanced Border
Bicycle Crossing Sign & LED Enhanced Symbol
In Surface Activation Device Only
Unibollard/ISAD Activation Unit (part as a pair w/ISAD)
Two Part Epoxy for Securing Base Plate Into Roadway (pass thru item)
Pad Mount Enclosure for Solar or AC Systems
A/C Power Control Unit Only - No Enclosure or Backpan
Separate 110VAC Wig-Wag Output Simultaneous w/ Signal Head Flashing
Separate 110VAC Output Simultaneous w/ Signal Head Flashing
Separate 12VDC Wig-Wag Output Simultaneous w/ Signal Head Flashing
Separate 12VDC Output Simultaneous w/ Signal Head Flashing
Upgrade LGS Controller for Novax Audible Alert
ADDENDUMS
This section is reserved for addendums typically applicable to various upgrade kits noted as optional
equipment in Section 1.6. Each addendum is supplied separately with appropriate upgrade kit.
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